Analyses of Linear Encoder Application (Glass Scale) On Quality of Machining Centre by Santiago M. Vilar
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Analyses of Linear Encoder Application (Glass Scale) On Quality of Machining Centre by Santiago M. Vilar
Diunggah oleh
Santiago M. VilarHak Cipta:
Format Tersedia
Politechnika
WROCAWSKA WYDZIA MECHANICZNY
PRACA DYPLOMOWA MAGISTERSKA
TEMAT:
Analyses of linear encoder application (glass scale) on quality of machining centre
Promotor: Realized by: Dr in. Zbigniew Kowal Santiago Manuel Vilar Blanco WROCLAW, Poland July 2010
Index
1.
Introduction..3
2.
Aim
and
range
of
necessary
analyses
of
linear
encoder
application
(glass
scale)
on
quality
of
machining
centre.3
3.
Define
by
drawing
a
dependency
diagram
quality
of
machining
centre5
3.1
Issues
needed
to
obtain
quality
of
machining
centre....17
4.
Design
of
geometric
models
for
simulation
of
machining
centre
in
FEM
method
4.1
Geometrical
model
of
the
machine
tool
with
ball
screw....19
4.1.1
How
to
design
geometrical
model.20
4.1.2
Assembly
the
geometrical
model..26
4.2
Geometrical
model
of
the
machine
tool
with
glass
scale28
5.
Boundary
conditions
for
finite
elements
thermal
models...37
5.1
Analysis
of
Power
Losses...37
5.1.1
Power
Losses
in
ball
screws..37
5.1.2
Power
losses
in
motors.41
5.1.3
Power
losses
in
bearings.43
5.2
Analysis
of
forced
and
natural
convection45
5.3
Machine
tool
model
for
analyze
temperature
with
SimDesigner
R2.48
6.
Machine
Tool
Model
for
analyze
deformation
with
CATIA
V5R17...58
6.1
Boundary
conditions
for
finite
elements
deformation
models..58
6.1.1
Define
connection
property
to
assembly
constrains..59
6.1.2
Load
data
of
temperature
distribution
obtained
by
SimDesigner
R2...66
6.1.3
Define
local
sensors
to
measure
deformations..67
7.
Design
plan
of
computing..70
1
7.1
Operating
conditions
and
positions.........70
7.2
Design
of
working
cycle...72
7.3
Selected
data
for
analyses....75
8.
Results
of
computing
and
conclusions75
8.1
Analyses
of
displacements
at
position
BEH..77
8.1.1
Analyses
of
work
cycle
with
initial
temperature
293K
at
BEH..77
8.1.2
Analyses
of
work
cycle
with
initial
temperature
295K
at
BEH..81
8.1.3
Analyses
of
work
cycle
with
initial
temperature
298K
at
BEH..82
8.1.4
Conclusions
at
position
BEH
with
different
initial
temperatures83
8.2
Analyses
of
displacements
at
position
CFG..85
8.2.1
Analyses
of
work
cycle
with
initial
temperature
293K
at
CFG.............85
8.2.2
Analyses
of
work
cycle
with
initial
temperature
295K
at
CFG.............87
8.2.3
Analyses
of
work
cycle
with
initial
temperature
298K
at
CFG.............89
8.2.4
Conclusions
at
position
CFG
with
different
initial
temperatures90
8.3
Conclusions
drawn
from
computing
analysis..91
9.
Conclusions
leading
to
improve
of
machining
centre
design.93
10.
Attachments..94
11.
References...132
1.
Introduction
Thermal
deformation
at
machining
centre
induces
errors
that
reduce
the
accuracy
in
precision
machining.
This
thermal
deformation
is
caused
by
high
speed
spindles
rotation
and
environment
changes.
There
are
a
lot
of
studies
in
order
to
reduce
these
errors
and
increase
accuracy
of
machining
centre,
which
information
was
taking
as
a
knowledge
base
for
this
project.
Some
of
these
papers
are
Particular
behavior
of
spindle
thermal
deformation
by
thermal
bending
by
Tae
Jo
Ko,
Tae-weon
Gim
and
Jae- yong
Ha;
Thermal
behavior
of
a
machine
tool
equipped
with
linear
motors
by
Jong-Jin
Kim,
Young
Hun
Jeong
and
Dong-Woo
Cho;
Thermal
Error
Measurement
and
Real
Time
Compensation
System
for
the
CNC
Machine
Tools
Incorporating
the
Spindle
Thermal
Error
and
the
Feed
Axis
Thermal
Error
by
H.J.
Pahk
and
S.W.
Lee.
The
solution
proposed
in
this
project
to
reduce
the
errors
caused
by
thermal
deformation
in
the
way
to
increase
accuracy
precision
machining
is
to
use
linear
encoders,
glass
scale,
to
determine
position
of
headstock
and
work
piece
by
reading
heads
to
these
linear
encoders.
2.
Aim
and
range
of
necessary
analyses
of
linear
encoder
application
(glass
scale)
on
quality
of
machining
centre
The
main
aim
of
this
project
will
be
to
recognize,
in
operational
conditions,
influence
of
machining
centre
thermal
behavior
on
machining
error
for
circular
encoder
where
position
of
headstock
and
work
piece
is
determine
by
number
of
rotations
of
the
ball
screw
and
linear
encoder
where
this
position
is
determine
by
reading
head
at
the
glass
scale.
This
aim
involves
the
following
range
of
project:
Working
out
geometric
model
suitable
for
simulation
of
machining
centre
in
FEM
method.
Preparing
such
data
as
material
constants,
bearings
preload
and
tolerances,
lubrication,
operating
conditions,
cooling
system
and
data
related
to
distribution
of
power
losses.
Working
out
FEM
model
for
simulation
of
temperature
distribution.
3
Working out FEM model for simulation of deformation. Determine factors influence on values of machining error for milling machine. Working out the plan of computing in chosen operating conditions and positions. Working out the result of computing. Creating a conclusion leading to improving of machining centre design by proper application of measuring system base on linear encoder.
Once we know the aim and the range of the project we have to say that the most obvious characteristic of the design problem is that it is complex because there are so many aspects like power losses, ambient temperature, materials thermal conduction and expansion coefficients, forced and natural convection, etc to our design problem. It is impossible to deal with all the aspects at once. Design problem have to be broken down into easy sub problems like build different models one for analyze temperature distribution and one for analyze deformation, which can be analyzed separately. The design process is open in the sense that the boundaries of the process are not limited. There are the undetermined goals, the means to achieve them, the issues and options to be considered, time and money and so on. These means that there is not a prescribed set of solutions, in other words, design calls for creativity and ingenuity. We are going to design a dependency diagram from idea of expert system creation as an assessment guideline for this project. An expert system is a collection normally composed of a knowledge base, the analysis of this knowledge and the end users interface. Knowledge acquisition for expert systems is a practical problem to be solved by experiments (in this project by computer simulation with CATIA V5R17 and SimDesigner R2 software). The knowledge that the expert provides varies with the context and gets its validity from its ability to explain data and justify the expert judgment.
3. Define by drawing a dependency diagram quality of machining centre A dependency diagram is a visual representation of the factors that affects to our project and the relationship of those factors. The dependency diagram is an essential tool for representing information and makes easy the rule creation process. The diagram consists of multiple nodes, rectangles, each of which represent an important factor to the problem. Nodes are connected by arrows that portray the dependencies which exist among the data variables. Variables which make a direct interference to the goal variable are referred to as first-level concept variables. Bottom-level concept variables are affected by raw data input variables. Raw data input variables directly accept input data from the expert system.
Raw input data variable values Raw input data variable values Raw input data variable values Raw input data variable values Bottom Level Concept variable values Bottom Level Concept variable values Second Level Concept variable values Second Level Concept variable values First Level Concept variable values GOAL First Level Concept variable values values
Fig
3.1
Dependency
diagram
format
[9]
Depending
on
the
problem
that
we
want
to
solve
there
are
three
possible
approaches:
goal-driven,
relationship-driven
and
data-driven.
In
most
of
the
cases
it
is
enough
to
construct
the
dependency
diagram
by
using
only
one
of
these
approaches,
but
it
could
be
possible
also
in
some
cases
to
use
a
combination
of
all
three
to
achieve
the
final
diagram.
To
use
the
goal-driven
approach,
specify
the
goal
first
and
then
ask
the
5
question what information does the expert system need to consider in order to make a decision about the goal? In this approach first specify top of the diagram (the goal variable) and work down toward the raw data input. The data-driven approach is used to construct a dependency diagram beginning by making a list of all know input data and information important to the problem domain. This method of drawing the dependency diagram uses a bottom-up approach. First specify the bottom level and work up toward specifying the goal variable. The relationship-driven approach is used to describe problems by outlining existing relationships which directly affect the outcome of a decision. With this approach, establish separate relationships by grouping them as intermediate, first and bottom-level concepts that eventually direct you to the goal variable and data input. Attending to the aim of this project, analysis on quality of a machine centre using a glass scale as a linear encoder, it is easy to choose the appropriate approach thinking that our goal is the main aim of this project. That is why we use the goal-driven approach to design our dependency diagram. First step to design the dependency diagram using the goal-driven approach is to identify the goal. In this project the goal is Analyses of application linear encoder (glass scale) on quality of machining centre. The variable used to represent this goal is called quality of machine tool. Bellow this variable there is a list of kind of values that the variable can accept as in figure 3.2
Fig 3.2 Identifying the goal variable Step two is to make a list of the items that need to be considered by the expert system to determine a value for the goal. These are the factors that determine how much quality of the machine tool is. It is a very important step in this project: To define in a
correctly
way
these
factors
to
design
the
best
possible
dependency
diagram,
because
this
diagram
is
going
to
be
the
roadmap
of
the
project.
To
know
which
factors
have
influence
on
machine
tool
quality
it
is
necessary
to
start
analyzing
all
the
different
possible
factors
and
then
choose
the
ones
that
really
have
a
direct
influence
on
the
goal.
In
general
terms
referring
to
the
accuracy
of
work
pieces,
the
errors
making
on
accurate
length
or
circle
and
in
testing
these,
should
be
no
greater
than
1.0-0.3
m.
The
base
guide
of
precision
surface-grinding
machine
should
be
made
so
that
the
deviations
from
linearity
should
be
no
greater
than
1-2
m
in
500
mm.
The
measuring
errors
in
testing
the
linearity
and
flatness
of
precision
guides
should
be
no
greater
than
0.0005
mm.
The
accuracy
of
the
machines
and
tools
depends
on
the
accuracy
of
the
measuring
systems
built
into
them.
About
the
measuring
systems
we
have
to
consider
the
errors
in
the
measuring
system
itself
(the
difference
of
the
nominal
and
actual
value
of
the
total
length
of
the
measuring
system
or
the
length
of
its
scale
divisions)
and
also
the
errors
in
testing
this
measuring
system.
A
major
proportion
of
the
errors
in
measuring
systems
depend
on
the
total
length
of
the
measuring
system
according
to
the
All-Union
State
Standard
12069-66,
should
be
expressed
in
the
form:
= ! + !"
Where a is the constant part and bl is the component of error depending on the length of the measuring system (temperature errors, misalignment of the measuring system, etc).
Fig 3.3 List of the formulas for linear displacements in different machines and also the classes of accuracy of graduated measuring systems which, according to the All-Union State Standard 12069-661, may be used as scales for these machines [6]. The temperature has also a big influence on the quality of a machine tool. The effects of the temperature must be analyzed to reduce thermal induced deformations in machine tools to avoid displacements between tool and work- piece. To solve this problem we need to do an analysis of different heat sources and how their deformations are. Failures on geometric of the work-piece can be produced by deformations on the machine tools, causes by internal and external heat sources.
The new standards for plane-parallel end-type length measuring systems in general correspond to the international norms indicated in the recommendations of the Comecon organization and also to the 1973 recommendation of the International Organization for the Unification of Measurements MOZM No. 30.
Fig 3.4 Illustrates different heat sources and different ways of heat transfer over the machine structure causing size and geometric errors in the measuring system, the machine structure and finally in the work-piece. [5] Heat sources can be classified as internal and external. Internal sources are basically heat produced by running the machine and the process of machining. External sources are changes in environment e.g. solar radiation, lightning etc. Referring to external heat sources, variation of the ambient temperature causes temperature vertical and horizontal gradients that cause thermo-elastic deformations of the machine tools. Figure 3.5 shows the solar energy radiation over a 12 month period for Frankfurt and the temperature range over the same time. Also shows the variation of the temperature in a machine shop. So the amplitude of the temperature will vary with geographical location, the season and the thermal characteristics of the machine shop.
Fig 3.5 Shows a not unusual variation of 5 oC during the winter and 15 oC during the summer time. [5] On figure 3.6 is illustrated how a rapid ambient temperature of 10 oC causes radial displacements on a lathe. During the first three hours after the temperature rise the distance between tool and spindle reduces quickly by 40 m followed by a low increase during the next 8 hours. This means that the machine has large time constants in reacting to ambient temperature changes.
10
Fig 3.6. Machine reaction to ambient temperature changes. [5] Thermal deformation also depends on the geometry of the machine. It is good to make equal the time constants for different components of the machine to reduce thermal deformations caused by external heat sources. Figure 3.7 shows this effect for a portal of a milling machine. Because of different wall thicknesses of the front and back of the column, the back gets warm up faster in the morning when the hall temperature rises and cools down more quickly in the afternoon than the front wall. This results also on a deformation of the machine. To avoid this effect, it is possible to insulate the thin wall with polystyrene, so the time constants can be more equal and the deformation cause by temperature changes were substantially reduced.
11
Fig
3.7
Shows
thermal
deformations
caused
by
external
heat
sources
on
a
milling
machine.
[5]
Referring
to
internal
heat
sources,
these
ones
directly
conduct
the
heat
into
the
machine
structure
and
causes
thermal
deformation.
One
of
the
most
important
heat
sources
is
the
spindle
system
and
its
bearing.
Depending
on
the
bearing
type
and
on
the
diameter
of
the
spindle
the
power
losses
can
be
up
100W
for
a
100mm
ball
bearing
running
at
10000rpm
and
up
to
1kW
for
a
hydrostatic
bearing
of
the
same
size
and
speed
rotation.
The
roller
bearings,
the
ball-screw
and
its
nut
must
take
in
consideration.
Due
to
a
study
of
Schulz
and
Schmitt
the
main
heat
source
is
the
ball
screw
and
its
nut.
Another
internal
heat
source
is
the
cutting
process
itself,
which
warm
ups
the
tool,
tool-holder,
work-piece
and
clamping
device.
In
the
same
way
the
table,
machine
and
other
components
can
also
be
heated
up
indirectly
by
hot
chips.
Making
an
analysis
of
all
these
information
it
is
possible
now
to
define
the
factor
that
have
a
direct
influence
on
the
quality
of
machine
tool
(goal).
This
quality
depends
on
one
side
by
the
design
conditions
of
the
work
piece;
this
is
the
accuracy
of
the
work
piece.
On
the
other
side,
quality
of
machine
tool
also
depends
on
the
error
that
the
12
machine makes at the production of the work piece caused by the different heat sources and ambient temperature variations. These variables are referred to first level concept variables. Variable names are going to be accuracy of work piece and machining error. In this case the values that these variables can accept are going to be the same in the two cases, m, as in figure 3.8. If value of machining error is X m and value of accuracy of work piece is Y m with X<Y then value of quality of machine tool is good. If value of machining error is X m and value of work piece is Y m with X>Y then value of quality of machine tool is poor.
Fig
3.8
Representing
first
level
concept
variables.
Step
three
on
designing
dependency
diagram
is
to
list
the
items
that
need
to
be
considered
by
the
expert
system
to
make
a
decision
about
each
first
level
concept
variable
listed
in
step
two.
This
step
is
basically
the
same
than
step
two
but
now
referring
to
the
first
level
concept
variables,
accuracy
of
work
piece
and
machining
error,
instead
to
the
goal
variable
(quality
of
machine
tool).
There
are
three
main
factors
that
have
influence
on
the
accuracy
of
work
piece.
First
one
is
the
final
work
piece
finish.
In
this
case
this
variable
is
going
to
be
called
as
roughness.
The
values
that
can
be
accepted
by
this
variable
are
going
to
be
also
m.
Second
one
is
the
range
of
values
where
dimensions
of
work
piece
must
be
to
be
considered
as
valid.
This
variable
is
going
to
be
called
tolerance.
There
values
that
can
be
accepted
by
tolerance
are
going
to
be
standard
tolerances
that
are
common
in
work
13
pieces for this machine centre, H/h 7,6,5. As we see on figure 3.9, table shows that there is a relation between tolerance and dimension of work piece; that is why dimension of work piece is going to be another factor with influence on the accuracy of work piece.
Fig 3.9 Tolerance table. As we can see there is a relation between the tolerances and dimension of work piece. Referring to the other first level variable, machining error, there are two main factors that have influence on it. In one hand we have errors on the work piece because displacement of the tool. The tool of the machine centre has direct dependency with the spindle, if the spindle varies the position the tool will move also. This variable is going to be called end of spindle displacement. On the other hand there are errors at the work piece because the work piece itself is no located at the exactly position. This variable is going to be called as displacement of work piece. As we can see on figure 3.10 there is now defined the second level concept variables.
14
Fig
3.10
Representing
the
second
level
concept
variables.
Next
step
is
to
define
the
factors
that
have
influence
in
the
second
level
concept
variables.
In
this
case
there
is
only
necessary
to
define
third
level
concept
variables
for
end
of
spindle
displacement
and
displacement
of
work
piece
because
these
second
level
variables
have
dependency
on
many
other
factors.
In
case
of
roughness,
dimension
of
work
piece
and
tolerance
of
work
piece
there
is
no
necessary
to
define
third
level
concept
variables
because
there
data
and
have
no
dependency
on
any
other
factors.
End
of
spindle
displacement
and
displacement
of
work
piece
have
their
dependency
on
the
same
factors
because
both
of
them
are
displacements
at
the
end.
Depending
on
the
configuration
of
the
machine
centre,
with
or
without
glass
scale,
the
displacement
at
these
two
points
should
be
different
as
different
should
be
the
behavior
of
the
machine
centre
during
thermal
deformation
for
these
two
different
configurations.
This
third
level
concept
variable
is
called
as
equipment
and
as
we
said
the
values
that
can
be
accepted
by
this
variable
are
ball
screw,
referring
to
machine
centre
without
glass
scale,
and
glass
scale
for
the
machine
centre
with
this
linear
encoder.
There
are
also
two
more
factors
that
have
influence
on
end
of
spindle
displacement
and
displacement
of
work
piece.
These
are
in
one
hand
the
position
where
the
machine
centre
is
working
and
where
it
is
going
to
work,
in
other
words,
the
direction
and
position
of
work.
On
the
other
hand
the
displacements
depend
also
on
15
the state before and during the working conditions of the machine centre. This factor is called as time. We can see third level concept variables in the next picture.
Fig 3.11 Representing the third level concept variables. Next step is to define the factors that have influence in the third level concept variables, direction & position and time. For the first one the factors are as it said direction of machining and position of machining. For the variable time, this depends on the cycle of machining and also on ambient temperature. All these four level concept variables there have no dependency on any other factors, there are data, that is why these four level concept variables are bottom level variables and that means that the dependency diagram is finally designed as we can see on the next picture.
16
Roughness Dimension of work piece Direction and Position
X Y Z
Direction
of
machining
X Y Z
Accuracy of work piece m
Tolerance of work piece
H7 H5 H6
Position
of
machining
X a Ya Za X b Yb Zb X c Yc Zc
A B C
Quality of Machine Tool Good Poor Machining Error m
End of spindle displacement
Equipment
Ball
Screw Glass
Scale
Cycle
of
Machining
rpm
Time
h
Displacement of w ork piece
Ambient Temperature
Fig
3.12
Dependency
diagram
for
analyses
of
linear
encoder
application
(glass
scale)
on
quality
of
machining
centre
3.1
Issues
needed
to
obtain
quality
of
machining
centre
The
dependency
diagram
shows
us
now
what
issues
must
take
in
account
to
obtain
good
or
poor
quality
of
machine
tool.
In
one
hand
we
must
attend
the
design
conditions
of
the
work
piece,
the
characteristics
that
we
want
the
work
piece
to
own,
like
the
roughness
and
the
tolerances.
In
the
other
hand
there
are
the
errors
we
made
during
the
process.
These
errors
at
the
end
depend
on
the
equipment,
direction
of
machining,
position
of
machining,
cycle
of
machining
and
ambient
temperature.
The
main
aim
of
this
project
is
to
analyze
all
this
factors
and
how
do
they
affect
together
to
the
quality
of
machine
tool.
We
will
see
how
errors
changes
if
also
changes
ambient
temperature.
Also
there
is
important
to
analyze
the
cycle
of
machining,
if
different
spindle
speed
rotations
has
or
no
influence
on
quality
of
machine
tool
or
if
for
the
same
spindle
speed
rotations
we
have
or
not
errors
depending
on
cycle
position.
As
we
see
on
figure
3.1.1,
work
cycle
for
this
project,
point
A
and
point
B
have
the
same
spindle
speed
rotation
but
the
thermal
conditions
and
deformations
may
not
be
the
17
same there are at different positions in the cycle. We will also analyze this in order to check if this difference has influence on quality of machine tool.
Point A
Point B
Fig 3.1.1 Point A and Point B have same spindle speed rotation but different position in the work cycle. Also it is important to analyze how direction of machining has influence or not on quality of machine tool as well as the position of the table and headstock of the machine centre. Figure 3.1.2, illustrates the three direction of movement each one with a ball screw. Every ball screws as is fixed by one side with the motor and slides at the other side. When machine starts working the thermal deformation will affect to these ball screws and displacement also will depend if the headstock or table is near the fixed point or not in order to the equation: ! = !"! Where L is the total displacement of the ball screw, is the expansion coefficient, L is the length between the nut and the fixed point of the ball screw and T is the increase of temperature of the ball screw.
18
Direction Y Direction Z
Position of work piece
Direction X
Fig 3.1.2 Directions of movement of headstock and table of the machine centre. 4. Design of Geometric Models for simulation of machining centre in FEM method 4.1 Geometrical Model of the Machine Tool with Ball Screw It is necessary to design a simple model of the machine tool in order to analyze it in the computer system. If we simplify the machine tool we will obtain short times of calculation. Simplify the machine tool means to delete all the parts that do not have influence on thermal behavior of the machine centre and also delete screws, shapes, pockets, chamfers, draft angles etc, because there are an unnecessary number of objects that are not necessary to be analyzed to compute displacements or Von Mises stress, because they have not a direct influence on the behavior of the machine tool. Figure 4.1.1 shows the production model of the machine tool while Figure 4.1.2 shows the geometrical model of the machine tool with ball screw, the one we are looking for.
19
Fig
4.1.1
Production
model
Fig 4.1.2 Geometrical model
4.1.1 How to design model The first step to obtain a geometrical model of the machine tool suitable to analyze it on CATIA is to delete all this aforementioned issues of the original machine tool model. The best way to do this is to start simplifying part by part. As we see on Figure 4.1.1 there are many parts and shapes that may be susceptible to delete, e.g. the holes of the base, the servomotors or the different chamfers. Figure 4.1.1.1 illustrates all the parts that have been deleted from the production model of machine tool:
20
21
22
23
Fig 4.1.1.1 illustrates all the parts that have been deleted from the production model of machine tool.
Second step is to simplifly all the non-deleted parts in order to obtain short time of computation. In some cases there is only necessary to delete holes, pockets and chamfers, but in other cases is also necessary to change the shape of the part so we can obtain a simple design. Figure 4.1.1.2 illustrates all the parts that have been modified from the production model:
24
Fig
4.1.1.2
illustrates
all
the
parts
that
have
been
simplify
from
the
production
model.
25
Once we have simplified all the parts, we need to fix them in their correct position by using the assembly constrains. After we have totally assembly the machine tool we can analyze it with SimDesigner and create a thermal model for determine temperature. This model is also the start point for create a second model for determine deformation by CATIA. 4.1.2 Assembly the geometrical model To obtain the machine tool model fully assembled, CATIA allow us to use a group of different assembly constrains. In this case it is enough to use only two of them to have assembly the machine tool. These are the contact constrain and the offset constrain. Contact Constrain Offset Constrain
Fig
4.1.2.1
Offset
Constrain
There
are
some
cases
where
it
is
important
to
make
sure
the
contact
constrain
makes
contact
between
two
parts
along
all
the
contact
surface
instead
of
making
the
contact
only
along
a
line.
These
are
the
cases
of
the
screws
with
the
house
bearings
as
we
see
on
figure
4.1.2.2.
To
obtain
the
correct
contact
between
these
two
parts
it
is
necessary
that
both
of
them
have
the
same
diameter.
If
not,
there
are
going
to
be
in
contact
after
using
the
assembly
constrain
but
the
contact
between
them
is
going
to
be
only
26
along a line. From the point of view of the assembly model this type of contact does not represent a problem, but it is from the point of view of the temperature model and deformation model, both of them created from this first assembly model.
Fig 4.1.2.2 contact between the screw and the house bearings To make sure that the assembly of the machine tool is done correctly it is necessary to explode the machine tool as we see on figure 4.1.2.3 and then do an update and check that all the parts are fixed in their correct positions.
Fig
4.1.2.3
final
aspect
of
geometrical
model
with
assembly
constrains
in
green.
27
4.2 Geometrical Model of the Machine Tool with Glass Scale This is a modification of the model with ball screw. To build this model it is necessary to design new parts and later assembly them to the machine model with ball screw. These new parts fixed together forms the glass scale. The glass scale is a linear encoder that measures the position of linear axes without additional mechanical transfer elements. With this linear encoder we eliminate positioning error due to thermal behavior of the ball screw. Optical encoders are normally used for high accuracy position measure system. In order to determine the position, the optical encoders generate two electrical signals that are combined using the arctangent algorithm [2]. In the case of this project these linear encoders are made up with an aluminum body that has inside the scale, the scanning unit and the guide way. The scanning unit is connected with the external mounting block as we see on figure 4.2.1. This encoders incorporates measuring standards made of periodic structures know as graduations. These graduations are applied to the glass so the absolute position information is read from the scale graduation as we see on figure 4.2.2
Fig 4.2.1 Simplified representation of the LS 186 Sealed linear encoder [1]
28
Fig 4.2.2 Graduations of absolute linear encoders and absolute code structure [1] This linear encoder operates on the principle of photoelectric scanning. As we see on figure 4.2.3, if the gaps between the scanning reticle and the measuring standard are aligned, light passes through. If the lines of one grating coincide with the gaps of the other, no light passes through. Photocell converts these variations on light intensity into sinusoidal electrical signals.
Fig 4.2.3 Scanning principle [1]
29
There
are
a
number
of
situations,
optical,
mechanical
and
electronic
that
affects
these
signals
and
produces
an
error
in
the
position
measurement.
This
error
is
important
not
only
for
metrological
purposes.
In
this
case
the
encoder
is
used
for
the
position
feedback
and
additionally
the
control
electronics
normally
uses
the
measured
data
in
order
to
get
the
speed
of
the
movement.
Then
the
positional
error
is
translated
into
the
speed
calculation
with
the
result
of
possible
modifications
on
the
dynamics
of
the
machine.
With
the
two
sinusoidal
electrical
signals,
the
relative
displacement
between
the
scale
and
the
reading
head
can
be
determined
using
the
arctangent
algorithm
in
this
way
!!"#$!% = !! arctan (!! )
[2]
!
where
!!"#$!%
is
the
value
of
the
displacement
when
it
is
calculated
by
the
arctangent
algorithm.
The
two
electrical
signals
can
be
described
in
this
way
!! = !! !! (2! ! + ! ) + !!
[2]
!! = !! !! 2! ! + ! + !!
[2]
where
!!
and
!! are
the
amplitudes,
!!
and
!!
are
the
background
levels,
!
and
!
are
the
phases
of
the
signals
and
!!
and
!!
are
the
functions
that
describe
the
shape
of
the
signals
with
min(F)
=
-1
and
max(F)
=
1.
For
the
ideal
case
the
parameters
of
the
equation
are
A1=A2=A,
B1=B2=0,
the
phase
between
signals
!
-
!
=
!
/2
and
the
two
signals
are
sinusoidal
F1
=
F2
=
sin.
With
non
ideal
electrical
signals,
the
relative
displacement
obtained
using
the
arctangent
algorithm
is
calculated
by
!""#" ! = ! !"# ! !!"#$!%
[2]
! !
30
where
mod
id
the
modulus
after
division
function.
Then
the
linear
term
of
the
series
expansion
with
respect
to
the
nominal
values
will
produce
an
error
that
is
described
as
! ! =
!"##$#(!) !" !!
! [2]
where g is any of the parameters of the electrical signals that may change from its nominal value go to go + g.
Fig 4.2.4 Experimental SA and SB sinusoidal signals. Theoretical signals are also shown. They perfectly fit the experimental data. [2]
Fig 4.2.5. Experimental error in the position measurement obtained when the measurement of the optical encoder is compared with an interferometer. Theoretical error obtained for the arctangent algorithm and for linear series expansion. [2]
31
In conclusion we can say that the accuracy of the linear measurement is determined by the quality of the graduation, the quality of scanning, quality of the signal processing electronics and the error from the scale guide way over the scanning unit, whereas this error con be reduced by using the arctangent algorithm. Deformations of the glass of the linear encoder can be caused by inappropriate assembly or as a consequence of modification by the structure of the machine tool in which the encoder is incorporated during working conditions. Glass scale is normally fixe to the machine tool in the middle and both sides and more if it is precisely. To make sure that the reading head is going to measure with the correct accuracy it is necessary to assembly the linear encoder with deviations less than 0,1 mm respect the measured direction.
Fig
4.2.6
Different
deformations
of
glass
scale
on
linear
encoder.
[3]
There
are
two
most
common
cases
of
deformation
of
the
glass
scale
(figure
4.2.6).
The
deformation
at
the
left
side
can
be
produced
by
two
causes.
First
one
because
the
surface
to
be
fixed
the
reading
head
it
is
not
flat
enough.
Second
one
because
of
changes
on
the
geometry
of
the
machine
tool
caused
by
changes
on
ambient
temperature
or
forces
on
the
machine.
Figure
4.2.7
shows
the
lost
of
accuracy
of
a
glass
scale
of
1
meter
of
length.
In
this
graphic
we
can
see
that
for
each
tenth
of
32
elevation on the middle of the glass scale, the linear encoder will have an error of 1,1 m.
Fig 4.2.7 Precision of a glass scale fixed on the bottom (with two different widths) to the machine tool. [3] In second case (figure 4.2.6, right side), this kind of deformation makes variations between the distances of the graduations of the glass scale (figure 4.2.2). This situation is typical of a glass scale only fixed to the body of the machine tool by right and left side. The weight of the glass scale makes this deformation (figure 4.2.8). In this case the deformation is up to 3,2 m for each tenth of deformation.
Fig 4.2.8 Precision of a glass scale fixed by right and left side to the machine tool. [3]
33
The just mentioned errors are the ones that owns to a glass scale but in case of this project the errors we want to recognize and remove are the displacements produced by thermal deformation caused by power losses. In case of model with ball screw these displacements, L, are calculated as the equation ! = !"! where is the thermal expansion coefficient of the ball screw, T is the temperature variation in the ball screw and L is calculated as ! = ! !! where n are the number of rotations at the motor and lD is the lead of the screw. For machine tool with glass scale the displacements, L, are going to be calculated in the same form ! = !"! but in this case is the thermal expansion coefficient of the glass, T is the temperature variation of the glass scale and L is the length from the fixed point of the glass scale (middle point of the glass case in our case) and the reading head. To obtain the geometrical model of the machine tool with glass scale, it is necessary to design by CATIA V5R17 the linear encoder. This linear encoder is going to be represented three new parts, the aluminum body (figure 4.2.9), the glass scale (figure 4.2.10) and the reading head (figure 4.2.11).
Fig 4.2.9 Aluminum body of linear encoder Fig 4.2.10 Glass Scale
34
Fig. 4.2.11 Reading head It is necessary also to do specific shapes to the body of the machine tool where we want to fix the linear encoder.
Fig 4.2.12 New shapes at the base of the table for supporting the glass scale. Attending to the three directions of movement of the machine tool (figure 4.2.13), there are a total number of seven possible combinations, glass scale on direction X only, direction Y only, direction Z only, directions XY, directions XZ, directions YZ and directions XYZ.
35
Fig 4.2.13 Shows glass scale X, Y and Z directions and new shapes to fix the aluminum body and reading head. The way to simulate a real glass scale with these three new parts is to fix together the reading head and the glass. We do this because in a real linear encoder, the reading head measures the position of the moving part in the glass and send this information another time as feedback to the motors at the screws to correct the position with the new information. If we fix the reading head to the glass we are simulating the real behavior of the glass scale, because this fixed point makes a dependency between the glass and the reading head like the feedback do. Also it is necessary to assembly the aluminum body of the glass scale to the body of the machine centre in a proper way. The middle point of the aluminum body must be fixed together with the body of the machine centre and also the aluminum body must by fixed at both side but in a way it will be possible to slide in that two points because of thermal deformation as we see on figure 4.2.14
36
feedback
Reading head is fixed to the glass
Slider point Fixed point
Slider point
Fig 4.2.14 In reality the reading head at the glass scale send feedback to the motors. This is simulated in our model by fixing the reading head to the glass. Also are illustrated the three points where the aluminum body is fixed to the machine body. 5. Boundary conditions for finite elements thermal models 5.1 Analysis of Power Losses There are different power losses while the machine centre is working. These are the power losses in the ball screws, in the bearings and in the motor. Power losses induce heat flux that produces thermal deformation on the machine centre. The value of some of the parameters needed to calculate power losses in ball screws are typical values from real working conditions. It is not necessary in this project to use the exact data for this machine centre to calculate power losses because the main object of the project is to compare the behavior of the machine with and without glass scale. This means that, using the same data to both different configurations of the machine centre, it will be possible to compare results in a proper way. 5.1.1 Power Losses in ball screw This kind of power losses are calculated according to the SKF formulas. First step is to calculate the theoretical efficiency
37
!=
1 !!! 1+ ! !
where the constant K is 0.018 for this type of ball screw according to SKF catalog, d0 is 47mm and the lead of the screw is 10mm. With these values is 0,992. Second step is to calculate the practical efficiency !! = !0,9 where p is 0,8298. Third step is to calculate the input torque in a steady state (Nm) by the way != !!! 2000!!! where F is the maximum load of the cycle (N) and according to normal values of working conditions is 800 N. With these values T is 0,1574Nm. Next step is necessary to calculate the power required in steady state, P != !!!! 60000!! where n are the rpm and in this case is 120 rpm according to normal values of working conditions. With these values P is 19,28W. With this result it is necessary to calculate the preloaded torque (Nm) according to the formula !!" = !!" !! 1 1 1000! !!
38
where
Fpr
is
the
preloaded
force
between
a
nut
and
the
shaft
(N)
and
in
this
case
is
1019N
according
to
normal
values
of
working
conditions.
With
these
values
Tpr
is
0,6656Nm.
Now
it
is
possible
to
calculate
the
power
preloaded
(W)
using
the
equation
!!"# = !!!!"
30
where
n
and
Tpr
are
the
same
above
so
Ppre
is
8,36W.
It
is
possible
to
define
the
power
losses,
P,
as
the
difference
between
the
electric
power
of
the
motor,
Pelec,
and
the
power
that
we
have
on
the
work
piece,
Pwork.
This
definition
is
represented
by
the
equation
! = !!"!# !!"#$
and
also
in
this
way
it
is
possible
to
define
the
Pwork
as
!!"#$ = !!"!#$ !!
so
power
losses
are
! = !!"#$ 1 !!"#$ = !!"#$ 1
!! !!
At
this
point
it
is
necessary
to
define
what
Pwork
means.
It
is
possible
to
define
it
like
the
sum
of
power
preloaded,
the
power
required
in
steady
state
and
the
power
of
inertia.
The
power
of
inertia
is
caused
by
the
masses
of
the
work
piece
and
table
but
in
this
case
power
of
inertia
is
going
to
be
considered
as
cero,
so
Pwork
can
be
calculated
using
the
equation
!!"#$ = !!"# + !
39
Considering
last
equation
power
losses
can
finally
be
define
by
the
equation
! = !!"# + !
Attending
to
these
equations
it
is
possible
to
calculate
power
losses
for
different
preloaded
force
between
nut
and
shaft,
Fpr
,
as
it
is
illustrated
un
the
graphic
power
losses
in
ball
screw
8
7
6
5
4
3
2
1
0
700
1019
1500
preload
[N]
1800
1 1 !!
power losses [W]
Fig 5.1.1.1 variation of power losses with rpm between nut and shaft To introduce these power losses to the model it is necessary to put them in the way W/m2, so they can be analyzed by SimDesigner as heat flux. To do that it is necessary to know the surface where the power losses are, so the heat flux will be the power losses divided by this area.
40
Fig
5.1.1.2
Illustrates
the
power
losses
in
the
ball
screw
X.
5.1.2
Power
losses
in
motors
According
to
Bernd
Bossmanns
research,
A
Power
flow
model
for
high
speed
motorized
spindle
power
losses
in
motors
can
be
calculated
by
the
equations
!!"#"$ = !!"#"$ !"# !!"#$ !"##$ !!"#$ !"#$
where
motor
max
can be calculated from engineering handbook Avallone and
Baumeister and spec speed and spec load are dimensionless values related to efficiency related to loads and speeds. The spec speed can be calculated from experimental data as !!"#$ !"##$ = 0,92 + !!"#"$ !"# 0,80 and the spec load can be interpolated from the following table
41
These
two
dimensionless
values
are
function
of
two
dimensionless
speed
and
load
variables
respectively
!!"#"$ !"# = !
!!"#"$
!"#"$ !"#
!"#$!"#"$ !"# = !
! !"#"$
!"#"$ !"#
Once
the
motor
is
calculated
it
is
possible
to
calculate
the
power
losses
in
the
motor,
Qmotor
(W),
by
the
equation
!!"#"$ = 2!!!"#"$ !!"#"$
In
the
case
of
this
project,
calculate
of
power
losses
in
the
motors
it
is
not
necessary
because
the
Company
provide
us
with
data
from
the
ACE
Series
VMD
450
(Machining
centre
of
this
project),
where
the
total
values
represents
the
power
losses
in
the
motor.
Power
losses
distribution
for
motor
idle
run Delivered
by
Factory
2000 127 1 128 4000 6000 8000 10000 12000 14000 16000 18000 20000 246 350 572 776 1090 1423 1796 2250 2701 3 9 7 8 14 27 32 33 35 249 359 579 784 1104 1450 1828 2283 2736 rpm W W W
1 !!"#"$ !!"#"$
s tator rotor total
42
3000
power losses [W]
Power losses in 20000rpm spindle load 0 kW
2500 2000 1500 1000 500 0 0 5000 10000 15000 speed rotational [rpm] 20000
stator rotor total
Fig
5.1.2.1
motor
power
losses
as
a
function
of
spindle
speed
It
is
necessary
to
convert
these
power
losses
from
W
to
W/m2
so
that
they
can
be
introduced
to
the
model
to
analyze
it
with
SimDesigner.
The
heat
flux
will
be
each
of
the
power
losses
divided
by
the
area
where
each
of
the
power
losses
has
influence.
rpm 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 Power
Losses
[W] Heat
Flux
[W/m2] 128 525 249 1020 359 1471 579 2373 784 3213 1104 4525 1450 5943 1828 7492 2283 9357 2736 11213
Fig
5.1.2.2
Values
of
power
losses
at
the
motor
expressed
in
[w]
and
[w/m2]
for
different
spindle
speed.
5.1.3
Power
losses
in
bearings
More
over
there
are
another
additional
heat
sources
in
mechanism
elements
like
ball
bearings
that
we
must
take
in
accounts.
Spindle
of
this
machine
centre
has
five
ball
43
bearings, four of them at the front and the last one at the rear side (figure 5.1.3.1)
Fig
5.1.3.1
headstock
section
of
the
machine
centre
with
the
components
that
generates
heat
during
the
working
conditions
and
also
the
cooling
system.
The
factory
also
provides
data
of
power
losses
at
the
bearings
for
different
loads:
Power losses in bearings as a function of spindle speed for load 0kW clearance W1= +10um, W2= -10um
60 50
Power losses [W]
40 30 20 10 0 0 5000 10000
Spindle speed [rpm]
bearing 1 bearing 2 bearing 3 bearing 4 bearing rear
15000
20000
Fig
5.1.3.2
Power
losses
at
the
bearings
as
function
of
spindle
speed
for
load
0KW.
It
is
also
necessary
again
to
divide
these
values
of
power
losses
by
the
area
of
each
of
the
bearings
in
the
way
to
have
power
losses
expressed
as
W/m2
so
they
can
be
introduced
to
the
SimDesigner
model.
44
rpm 2000 3000 8000 12000 20000
load 0KW power l osses [w] bearing 1 bearing 2 7,6 7,6 12 12 19 19 30,1 31 54 55,6
bearing 3 7,6 12 18 28 48,6
bearing 4 rear bearing 7,6 2,8 12 4,6 19 14,8 30,1 22,6 53,6 35,9
heat flux [W/m2] bearing 1 190 300 475 752,5 1350
bearing 2 190 300 475 775 1390
bearing 3 190 300 450 700 1215
bearing 4 190 300 475 752,5 1340
rear bearing 175 287,5 925 1412,5 2243,75
Fig 5.1.3.3 Values for power losses at bearings expressed in [W] and [W/m2] for different spindle speed and load 0KW. 5.2 Analysis of forced and natural convection In terms of surface convection it is necessary to define two kind of surface. First one is the surface exposed to natural convection. These surfaces are all ones of the machine centre in contact with ambient, called natural convection. Second kind is the one exposed to cooling systems or forced convection. In case of this project, the machine centre has a cooling system for the motor and bearings that affect to the surface of the headstock. These two different kinds of convection translate in two different values of coefficient [W/Km2].
Fig 5.2.1 The sketch represents the pockets for the oil of the cooling system for motor and bearings (see figure 5.1.3.1) It is necessary to calculate coefficient in case of forced convection. As it is illustrated on figure 5.2.1, the sketch represents the ways for the cooling liquid around the stator and the bearings. The value of coefficient it is determinate by Reynolds number and
45
Re*Pr*dhb/l
where
Pr
is
the
Prandtl
number.
According
to
this
there
are
three
possible
coefficient
If
Re*Pr*dhb/l
<
4,5
and
Re
<
Recrit
(laminar
flow)
then:
! = !0,5!"!"!!/!!"#$%"/!!
If
Re*Pr*dhb/l
>
4,5
and
Re
<
Recrit
(laminar
flow)
then:
! = !1,86 !"!"!!/!
If
Re
>
Recrit
(turbulence
flow)
then:
! = !0,023!" !,! !" !,! !"#$%"/!!
where
dhb
is
hydraulic
diameter
!! = ! !!!
the
constant
k
is
calculated
by
the
way
! = 1 + 1,772 !!
!
! !,!!
!"#$%"/!!
There is data of coefficient for stator, rear and front bearings. As it is illustrated forward, the value of coefficient depend on the quantity of cooling liquid, in this case oil. The values of coefficient used for compute with SimDesigner there are the ones for 20 l/min of oil quantity. For surface without forced convection, the ones in contact with ambient, coefficient has always the same value, 10 W/Km2, that it is a typical value from real working conditions.
46
600 alfa [W/mK] power losses [W] 400 200 0 5 10
stator cooller - oil cooling
Convection coef.
oil quantity [l/min] 15 20 25 30 35 40
Fig
5.2.2
Variation
of
coefficient
and
power
losses
with
cooling
liquid
in
stator.
front bearings cooler
500 alfa [W/mK] power losses [W] 400 300 200 100 0 5
Convectio n coef.
oil quantity [l/min] 10 15 20 25 30
Fig
5.2.3.
Variation
of
coefficient
and
power
losses
with
cooling
liquid
in
front
bearings.
rear bearings cooler
700 600 alfa [W/mK] power losses [W] 500 400 300 200 100 0 5
alfa
oil quantity [l/min] 10 15 20 25 30
Fig
5.2.4
Variation
of
coefficient
and
power
losses
with
cooling
liquid
in
rear
bearing.
47
5.3 Machine Tool Model for analyze temperature with SimDesigner R2 The start point of this model is the Geometrical Model of Machine Tool with Glass Scale. The aim of this part of the project is to obtain the temperature distribution of heat flows along the machine tool produced by the power losses, natural and forced convection. The election of the geometrical model with glass scale against the model with ball screw it is because it is necessary to determine data of this distribution of all the parts of the machine centre. Geometrical model of machine tool with glass scale is the same model than the ones with ball screw but with extra parts, the ones that represents the glass scale. Data for temperature distribution for geometrical model of machine tool with glass scale it would be suitable also for model with ball screw as long as both model have their moving parts in the same position. This analysis was do it with SimDesigner R2 compatible with CATIA V5R17.
Fig
5.3.1
Temperature
distribution
computed
by
SimDesigner
R2
along
the
machine
tool
produce
by
power
losses
and
natural
and
forced
convection.
48
The process of designing this model starts by defining thermal properties of all materials of the machine centre. It is necessary to define up to three properties, thermal conductivity, specific heat and emissivity. In case of thermal conductivity the value for all materials of the machine centre is going to be 40 W/mK that it is a normal value from real experimental data. In case of specific heat also there is going to be one value for all materials, 0,5 KJ/kgK, and it is also a normal value for real working conditions. In case of the emissivity all materials are going to have also the same value, cero.
Fig 5.3.2 Thermal properties of materials: Thermal conductivity, Specific heat and emissivity. Next step is to define the boundary conditions. In case of this project the boundary conditions are the initial temperature . Initial temperature is a parameter that
affects the reaction of the machine tool against the power losses, so it is an important parameter and also it is a parameter as we can see along this project susceptible to select different values to study different behaviors. In first case value for initial temperature is normal ambient temperature, 293 K for all the parts of the machine centre.
49
Fig 5.3.3 Value for initial temperature for all parts of machine tool. In first case this value is ambient temperature. This initial temperature is the boundary conditions of thermal model. After defining the boundary conditions it is necessary to define thermal loads. These are going to be the all the heat flows and different type of convections the machine tool is affected. In case of this machine tool as it is define on this project, is going to be affected by power losses, forced and natural convection. Power losses are heat flows and CATIA V5R17 gives us the possibility to introduce heat flows by two different ways. In our case the proper way to do this is selecting Heat Flux , because there are in
the form [W/m2]. This is the correct way to introduce power losses [W] to the model, if we know the area [m2] where the power losses are, finally we will know power losses as heat flux. As we seen on figure 5.3.4 read arrows indicates power losses as heat flux through the selected surface. For power losses in the ball screw the selected area for the heat flux are the spindles, because the ball screw moves along the spindle so the power losses affect along this surface. In this machine tool there are going to be power losses in the three different ball screws and also power losses in the motor. It is important to define as much heat flux as power losses are in the way to be able to select different values of heat flux for each different power losses.
50
Fig 5.3.4 Indicates heat flux by red arrows in the ball screw X. There are also, apart from power losses in the three ball screws, power losses in the motor. These power losses are the ones at the stator and the ones at the bearings. In case of the motor of this machine tool we have five different bearings, four front bearings and one rear bearing. This makes a total of six different heat fluxes to represent the power losses in the motor, the ones at the stator and the ones at the five different bearings. To introduce these power losses the area selected is the interior of the heat stock as we see on figure 5.3.5 for all the six different heat fluxes that represents power losses in the motor and bearings.
51
Fig 5.3.5 Power losses in the motor represented by red arrows as heat flux through the heat stock. Once all of the different power losses are introduced as different heat fluxes to our model it is necessary to define the different convections the model is affected by.
This model has two different types on convection, natural and forced. All natural convections are marked with blue cones along the selected surface as we can see on figure 5.3.5. There is natural convection in all the surfaces in contact with ambient and it is not necessary to define as much convection loads as surface in contact with ambient for natural convection because for all of them the properties are the same, 10 W/Km2 for convection film coefficient and 293 K for reference sink temperature. The values for these convection properties are normal values from typical working conditions.
52
Fig 5.3.6 Typical values from working conditions for natural convection properties. There is forced convection in the motor, particularly in the stator and in the five different bearings. This means that we need to define up to six different forced convections. As we did with power losses in the motor, the selected area to introduce these six convections is the interior of the head stock.
Fig
5.3.7
Shows
forced
convection
in
the
stator.
It
is
represented
by
the
blue
cones
inside
the
head
stock.
53
To make sure that the machine tool for analyze temperature with SimDesigner is proper done, this means, that the different heats flows perfect with no interruption along all the surface of the machine tool it is necessary in some parts of the machine tool to select the proper mesh in order to obtain this correct flow of the heat. This means that in some parts of the machine tool because of the difference between the size of the mesh of two parts in contact, if this difference is too big, could happened that the heat do not flows in the correct way along the two surface in contact. Better solution to solve this problem is to define local mesh in one of the surface in contact to make more similar to the other surface so in this way there will be no problems of bad connection between nodes. To do this it is necessary to add to the mess of the part where we want to change the mesh at the surface, a local size and local sag and define the supported surface and the values for local mesh sag and local mesh size as we see on figure 5.3.8. The advantage of changing only the mesh of the surface instead the mesh of all one part it is that compute time is going to be shorter.
Fig 5.3.8. Definition of local mesh
54
Correct contact between different mesh
Fig 5.3.9 Shows local mesh at the base of the machine tool next to the house bearing and also local mesh at the house bearing next to the end of spindle in order to have good contact between nodes. To prove that the contact between local mesh as we see on figure 5.3.9 is correct is possible to choose a value for, in this case heat flux at the ball screw X, big enough to see if the heat flows in a correct way from one part to the other. This is illustrated on figure 5.3.10, as we can see the temperature values is not important in this case but it is the fact that there is a flow of heat from the spindle to the house bearing and from this to the base of the machine tool. That means that there is a correct contact between parts because of the new local mesh.
55
Fig 5.3.10. Shows how heat flows in a correct way from the spindle to the house bearing and from this one to the base of the machine tool. Once the model is ready is possible to compute and generate image
to obtain the temperature field fringe and after it will be possible to export data as a text file to use it as temperature field and analyze deformation of machine tool with CATIA V5R17.
56
Fig 5.3.11 Shows how to select temperature field fringe and save it as data on to a text file to analyze it later with CATIA V5R17.
Fig
5.3.12
Machine
tool
model
with
glass
scale
temperature
distribution
at
positions
BEH
(left)
and
CFG
(right)
with
initial
temperature
293K.
57
6. Machine Tool Model for analyze deformation with CATIA V5R17 6.1 Boundary conditions for finite elements deformation models The aim of this part of the project is to obtain two different models, one for ball screw configuration and other for glass scale, ready to analyze them with CATIA V5R17 and obtain the deformation produced by power losses and natural and forced convection on the machine centre. The starting point is going to be the geometrical model of machine tool, one for each configuration. Basically we need to do three steps to obtain each model. First step is to add to every assembly constrain a proper connection property so the relative move between the parts in contact will be the one in the correct direction. Second step is to load the data of temperature distribution obtained by SimDesigner R2 in a proper way. This data represents the temperature distribution of heat flow caused by power losses and natural and forced convection. Third and final step is to create as much as local sensors needed to measure the deformation of the machine centre in a correct way so we can compare results for both model in the way to decide which model has more accuracy for which working condition.
Fig
1.
Shows
deformation
computed
by
CATIA
VR517
produced
by
power
losses
and
forced
and
natural
convection
of
the
machine
tool.
58
6.1.1 Define connection property to assembly constrains The process of designing this model begins with the necessity of using one restraint, the clamp , and it is necessary to add it to the base on the machine tool in order to
simulate that it is fixed to the ground as it is illustrates in figure 6.1.1.1
Fig 6.1.1.1 Illustrates the clamp at the base of the machine tool. The clamp fixes the machine tool to the ground. To add properties to the assembly constraints in case of this machine tool it is only necessary to use two types of connection property. These connection properties are the slider connection property and the fastened connection property . With
the
first
one,
slider
connection
property,
the
bodies
in
contact
by
the
assembly
constrain,
will
move
one
through
the
other
during
the
deformation
but
always
keeping
the
contact
between
them.
As
we
will
see
later
it
will
be
important
to
define
the
direction
where
we
want
to
move
the
parts
when
we
use
the
slider
connection
property.
With
the
fastened
connection
property
the
bodies
in
contact
by
the
assembly
constrain
will
keep
the
same
relative
position
between
them
during
the
deformation.
There
is
only
one
way
of
thinking
at
the
time
to
choose
between
slider
and
fastened
connection
property.
This
means
that
all
part
that
is
fixed
to
another
part
by
right
and
left
side
it
is
going
to
deform
by
the
two
sides,
so
in
one
side
should
be
fixed
to
the
other
body
as
fastened
connection
property
and
on
the
other
side
should
be
fixed
as
slider
connection
property
in
order
to
avoid
that
the
part
breaks
during
the
deformation
as
we
can
see
on
figure
6.1.1.2
59
moves
fixed
Fig
6.1.1.2
The
house
bearing
is
fixed
to
the
base
of
the
machine
tool
on
the
right
side
by
fastened
connection
and
on
the
left
side
by
slider
connection
property
in
order
to
avoid
that
the
part
breaks
during
the
deformation
of
machine
tool.
This
approach
must
be
for
all
the
parts
in
the
same
situation.
In
case
of
screws
the
way
of
thinking
is
the
same
but
the
slider
connection
property
must
be
at
the
side
of
the
bearing
and
it
must
be
also
fastened
at
the
side
of
the
motor.
This
is
because
the
fastened
connection
property
simulates
that
the
motor
moves
the
screw
and
only
the
screw
can
deforms
in
the
side
of
the
bearing.
fixed
moves
Fig
6.1.1.3
Illustrates
how
the
screw
is
fixed
as
fastened
on
the
right
side
where
it
is
the
motor
(not
illustrated)
and
also
fixed
as
slider
connection
on
the
left
side
where
it
is
the
house
bearing
60
In case of the blocks, first it is necessary to define the behavior against the rail. The block must slide by the rail in all the surfaces where there is contact between the two parts as we see on figure 6.1.1.4
moves
moves
Fig 6.1.1.4 Shows the relative move of a block against the rail. It must be slider in all surface where there is contact between block and rail. Second it is necessary to define the behavior of the blocks against the table, headstock and body of the machine tool. In all cases the approach is the same than in the other cases. Blocks of one side must be fixed to the part as fastened and blocks from the other side must be fixed as slider connection property. It is important as we said to define the direction where we want to make the blocks slides through. In case of the blocks of the table the ones at the right side are fixed as fastened connection property to the table as we can see on figure 6.1.1.5 The ones at the left side must slide in Y direction. To force the blocks from the left side to move in the correct direction during the deformation it was necessary to design a special shape to the bottom side of the table as we can see on figure 6.1.1.6. To make this apart from the special shape we need to add slider connection property to the assembly constrain between the left side blocks and the new shape.
61
moves
fixed
moves fixed
Fig 6.1.1.5 Shows the blocks that must be fixed in their position and the ones that must slide through the correct direction in order to avoid that the guide breaks during the deformation.
moves
moves
Fig 6.1.1.6 Shows how the blocks at the left side of the table slide through the new shape in the correct direction.
62
These
special
shapes
are
also
necessary
on
the
headstock
and
on
the
other
moving
part.
fixed
moves
fixed
moves
Fig 6.1.1.7 Shows the direction of movement of the blocks through the new shapes at the backside of the headstock.
moves
moves
fixed
fixed
Fig
6.1.1.8
Shows
the
direction
of
movement
of
the
blocks
through
the
new
shapes
at
the
backside
of
this
moving
part.
63
Once all the assembly constrains have their own connection property it is important at this point to make a difference between the configuration of model with glass scale and the one without glass scale (ball screw model). For model of machine tool with ball screw the property associated to the assembly constrain between the ball screw and the spindle itself must be fastened connection property so that the ball screw moves together with the spindle during the deformation as we see on figure 6.1.1.9. This approach must be the same for the rest of the ball screws and spindles in case of machine tool with ball screw configuration.
fixed
Fig 6.1.1.9 Illustrates the fastened connection property for the assembly constrain between the ball screw and the spindle in the machine tool model with ball screw. In case of model of machine tool with glass scale, the connection property associated to the assembly constrain between the ball screw and the spindle must be slider connection, but at the same time, the connection property of the assembly constrain between the reading head and the glass scale must be fastened connection, as we see on figure 6.1.1.10. Doing this, we are simulating the effect that the reading head has on the machine tool. This means that if we fastened the reading head to the glass scale itself, we are simulating the feedback that the reading head sends to the motors to act through the position of the ball screw. This approach must be the same for the rest of ball screws and reading heads in case of machine tool with glass scale model.
64
moves fixed
Fig 6.1.1.10 Shows the reading head fastened to the glass scale while the ball screw is slider through the spindle for the machine tool with glass scale model. Continue with model of machine tool with glass scale it is necessary to define how they are the connection properties of the assembly constrains of the glass scale. For all of the tree glass scale that the machine tool is up to be equipped, the connection properties for the assembly constrains are always the same. The glass scale it is formed by two parts, the aluminum body and the glass itself. The aluminum body is the one fixed to the body of the machine tool. This part must be fastened in the middle point and slider at left and right side. The glass must be fixed, normally in the middle point, to the aluminum body by fastened connection property as we can see on figure 6.1.1.11
65
fixed
moves
moves
Fig 6.1.1.11 Shows how connection properties of assembly constrain of glass scale must be. 6.1.2 Load data of temperature distribution obtained by SimDesigner R2 At this point, where all the assembly constrains have their own proper connection property for both models, one with ball screw and other with glass scale, it is necessary to load the data with temperature distribution that we obtain from the computing of SimDesigner R2. To do this, first is necessary to modify this data in the correct way to make it compatible for CATIA V5R17. As we see on figure 6.1.2.1, it will be necessary to delete the marked lines to make it compatible with CATIA V5R17 before load it.
Fig 6.1.2.1 Shows data with temperature distribution computed by SimDesigner R2. It is necessary to delete the marked parts to make it compatible with CATIA V5R17.
66
Once this data is ready we can load it to our model for analyze deformation with CATIA V5R17 as temperature field . As we can see on figure 6.1.2.2 the correct way to
load this data is by selecting 1 Kdeg the temperature. Doing this CATIA V5R17 multiplies the values from the data with the value on Temperature. If we select as Temperature 1 kdeg we will have the same values from the data on our model at CATIA V5R17.
Fig
6.1.2.2
Shows
how
to
load
the
data
from
SimDesigner
R2
to
CATIA
V5R17
in
the
correct
way.
6.1.3
Define
local
sensors
to
measure
deformations
At
this
point
it
is
now
possible
to
add
local
sensors
to
both
models
to
measure
the
deformation
produce
by
the
power
losses
and
natural
and
forced
convection.
It
is
only
necessary
to
add
the
sensor
we
think
they
will
give
us
useful
data.
The
sensors
are
going
to
be
in
the
same
points
for
both
models,
with
and
without
glass
scale,
in
order
to
compare
results.
There
are
going
to
be
three
sensors
per
selected
point
so
we
can
measure
the
displacement
on
the
three
directions.
The
selected
points
are
going
to
be
the
end
of
spindles,
one
corner
of
the
table
and
also
the
middle
point
of
the
head
stock.
This
makes
a
total
of
15
sensors
per
model.
In
case
of
the
sensors
of
the
middle
point
of
the
headstock
it
is
necessary
to
design
a
new
shape
at
the
end
of
the
headstock
so
we
can
select
the
middle
point.
Figure
6.1.3.1
illustrates
the
new
shape
at
the
end
of
the
head
stock
and
the
values
of
the
sensors.
It
was
chosen
this
point
to
67
simulate the measure at the tools so we can obtain their displacements during the deformation.
Fig 6.1.3.1 Shows the new shape at the end of the headstock and the value of sensors at the middle point. There are two kind of sensors that measures displacement as we can see on figure 6.1.3.2. These are the Displacement Magnitude and the Displacement Vector.
Fig 6.1.3.2 Illustrates the two types of sensor that CATIA V5R17 allows to choose to measure displacement.
68
To choose between these two kinds of sensors in our case we want to measure the displacement in the three directions of each point. As we see on figure 6.1.3.3, the displacement could be different (black arrows) at the time that the magnitude vector (red arrows) could be the same. Attending to this, in our case we must choose displacement vectors.
Fig 6.1.3.3 Shows the difference between displacement and magnitude vectors. In our case we need to choose sensors as Displacement vector in order to measure the displacement of the point in the tree axis. Now it is possible to compute, illustrated on figure 6.1.3.4. , and generate image, , of the
deformed mesh to have final model for analyze deformation with CATIA V5R17 as it is
Fig
6.1.3.4
Shows
deformed
mesh
of
geometrical
model
with
glass
scale.
The
values
marked
as
red
indicates
position
and
measure
by
the
local
displacement
sensors.
69
7.
Design
plan
of
computing
Before
starts
work
cycle
there
are
no
power
losses
in
bearings/motor
and
spindle
speed
rotation
equals
to
zero
so
there
will
be
no
thermal
displacements.
Working
conditions
starts
with
initial
temperature
equals
to
ambient.
These
conditions
changes
gradually
with
time
due
to
machine
working
cycle,
because
of
different
spindle
speed
rotations,
variations
in
ambient
temperature,
different
headstock
and
table
positions.
All
these
phenomena
are
the
sources
of
different
power
losses
and
different
displacements
causes
by
thermal
deformation.
As
we
see
on
the
dependency
diagram
we
focus
on
the
factors
that
we
consider
have
influence
on
quality
of
machine
tool.
But
there
is
impossible
to
study
the
influence
of
these
factors
all
at
the
same
time.
It
is
necessary
to
separate
analyses
for
different
working
conditions
in
order
to
obtain
relations
between
these
working
conditions
and
displacements
so
we
can
define
behavior
of
machining
centre.
7.1
Operating
positions
and
conditions
The
proposed
studies
are
analyzing
changing
of
displacements
in
chosen
points
during
work
cycle
with
three
different
Ambient
Temperatures
(293K,
295K
and
298K)
and
two
different
headstock/table
positions,
position
BEH
and
position
CFG,
as
we
see
on
figure
7.1.1.
These
studies
were
done
with
software
CATIA
V5R17,
for
analyze
thermal
deformation,
and
SimDesigner
R2
for
analyze
temperature
distributions.
Positions
are
defined
in
picture
7.1.1.
The
positions
are
not
random
positions,
there
are
in
the
middle
and
in
both
sides
of
glass
scale.
Machine
centre
has
one
glass
scale
for
each
direction
X,
Y
and
Z.
We
select
three
points
per
glass
scale,
one
in
the
middle
and
two
at
both
sides.
Also
there
are
not
random
points.
The
ones
at
the
middle
of
the
glass
scale
it
were
chosen
because
we
suppose
it
is
the
point
where
glass
scale
makes
smaller
error
because
glass
scale
is
fixed
in
the
middle
as
fastened
connection
property
so
in
this
point
L0
so
the
displacement
should
be
the
smallest
in
order
to
! = !"!
70
If we select three points per glass scale, this makes a total of 27 possible combinations of different headstock/table positions. The two selected, BEH and CFG were selected to analyze behavior of machine centre in two different positions. First one, position BEH, was chosen because it is the one in the middle of the three glass scales. Second position, CFG, was chosen in order to analyze other position different to the first one. In this case no one of the reading heads are in the middle of the glass scales. Ball screw X and ball screw Z are at the opposite side of the motor and ball screw Y is close to the motor. This should means that for ball screw X and ball screw Z must be L=Lmax so displacement should be maximum in order to ! = !"! but for ball screw Y must be L0 so the displacement should be minimum according to the same equation.
C D E F F
H G
I G
Fig 7.1.1 Shows the two selected positions of the headstock and table, BEF and CFG, for our studies.
71
7.2 Design of working cycle To reach proposed studies it is necessary to design a work cycle that imitates real machine working conditions. Once we have designed this cycle, we can compute temperature distribution and thermal deformation for defined FEM models. The work cycle must have some requirements such as representative spindle speed rotation along all speed range; realistic machining times in order to observe real machine tool displacements and enough time steps to extract as much data as necessary. In figure 7.2.1 we can observe the work cycle that is going to be used for our studies. In this work cycle machine centre starts working 8000 r.p.m. during first hour. This value of spindle speed rotation was chosen in order to analyze behavior of machine centre working nearly the middle range of r.p.m. During the second hour the machine centre stops working so we will analyze what happens with thermal deformation during a time without heat sources and after that stars working at maximum spindle speed rotation, 20000 r.p.m. during another hour. After the third hour continues working at 8000 r.p.m. for another hour and finish the work cycle.
Fig 7.2.1 Work cycle used in the different analyses of this project.
72
Attending to the work cycle it is necessary to introduce the power losses not as constant but as transient values to machine tool model for analyze temperature with SimDesigner R2 as we see on figure 7.2.2 and figure 7.2.3
Fig 7.2.2 Shows how to introduce power losses as a transient value to SimDesigner model.
Fig 7.2.3 Illustrates how to introduce, in this case for stator, transient power losses and transient forced convection according to our work cycle.
73
Fig 7.2.4 Power losses as heat flux in stator during work cycle. The graphic has the same form than the work cycle.
Fig 7.2.5 Forced convection at stator. This graphic do not have the same form that the work cycle because forced convection does not depends on spindle speed rotation, depends of quantity of oil cooling flow.
74
7.3 Selected data for analyses Power losses at the motor
rpm 8000 20000 Power Losses [W] Heat Flux [W/m2] 579 2373 2736 11213
Power losses at the bearings
bearing 3 18 48,6 heat flux [W/m2] bearing 4 rear bearing bearing 1 bearing 2 19 14,8 475 475 53,6 35,9 1350 1390 bearing 3 450 1215 bearing 4 rear bearing 475 925 1340 2243,75
rpm 8000 20000
power l osses [w] bearing 1 bearing 2 19 19 54 55,6
Constant ball screw (X, Y and Z) power losses: 64,04 W/m2 Oil cooling flow: 20 L/min Free film convection value: 10 W/Km2
8. Results of computing and conclusions All the results and graphics of the project are shown in the attachment. In this section there are shown only the ones which can give us information about behavior of machine centre.
Fig
8.1Machine
tool
model
with
glass
scale
temperature
distribution
at
position
BEH
with
initial
temperature
293K.
75
Fig 8.2 Machine tool model with glass scale deformation at position BEH with initial temperature 293K.
Fig
8.3
Machine
tool
model
with
glass
scale
temperature
distribution
at
position
CFG
with
initial
temperature
293K.
76
Fig
8.4
Machine
tool
model
deformation
at
position
CFG
with
initial
temperature
293K.
8.1
Analyses
of
displacements
at
position
BEH
8.1.1
Analyses
of
work
cycle
with
initial
temperature
293K
at
BEH
Result
for
displacements
(mm)
during
work
cycle
with
initial
temperature
293K
at
position
BEH:
GLASS SCALE T=293K Position BEH time (s) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
dispacement (mm)
sensor ball screw X
ball screw Y
ball screw Z
tool
table
displacement direction X Y Z X Y Z X Y Z X Y Z X Y Z
3600 0,0120 0,0003 0,0009 0,0009 0,0300 0,0020 0,0020 0,0040 0,0210 0,0030 0,0170 0,0370 -0,0010 0,0006 0,0010
7200 0,0170 0,0005 0,0009 0,0010 0,0480 0,0010 0,0030 0,0040 0,0290 0,0110 0,0110 0,0250 -0,0009 0,0005 0,0010
10800 0,0190 0,0005 0,0008 0,0010 0,0600 0,0001 0,0080 0,0090 0,0470 0,0240 0,0630 0,1270 -0,0008 0,0004 0,0010
14400 0,0200 0,0005 0,0008 0,0010 0,0700 -0,0006 0,0110 0,0090 0,0500 0,0500 0,0260 0,0530 -0,0007 0,0003 0,0010
77
BALL SCREW
T=293K
Position BEH time (s) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
dispacement (mm)
sensor displacement direction ball screw X X Y Z ball screw Y X Y Z ball screw Z X Y Z tool X Y Z table X Y Z
3600 0,0110 0,0003 0,0009 0,0009 0,0300 0,0020 0,0010 0,0140 0,0200 0,0040 0,0280 0,0450 0,0080 0,0006 0,0010
7200 0,0160 0,0004 0,0008 0,0010 0,0470 0,0009 0,0030 0,0200 0,0270 0,0110 0,0280 0,0380 0,0130 0,0005 0,0010
10800 0,0190 0,0004 0,0008 0,0010 0,0600 0,0003 0,0070 0,0280 0,0450 0,0260 0,0830 0,1500 0,0150 0,0004 0,0010
14400 0,0200 0,0005 0,0007 0,0010 0,0700 -0,0008 0,0110 0,0330 0,0490 0,0510 0,0510 0,0810 0,0160 0,0003 0,0010
Attending to these results we can observe that: Displacement of ball screw X (ball screw in X direction) of course is the same for ball screw configuration (without glass scale) and with glass scale in the three X, Y and Z directions because glass scale has no influence at the end of the ball screws. This is useful to probe that both models, with and without glass scale, are well done. Conclusion: Glass scale does not improve ball screw X displacement in X, Y and Z directions. Displacement of ball screw Y (ball screw in Y direction) is of course the same for ball screw and for glass scale in X, Y and Z directions. Conclusion: Glass scale does not improve ball screw Y displacement in X, Y and Z directions. Displacement of ball screw Z (ball screw in Z direction) is practically the same for ball screw and for glass scale in X and Z direction but not in Y direction where there is displacement for ball screw bigger than the one for glass scale of 0,01 mm at the first hour, 0,016 mm at the second hour, 0,019 mm at the third hour and 0,024 mm at the fourth hour.
78
ball
screw
Z,
displacement
in
Y
during
work
cycle
with
iniaal
temperature
293K
at
posiaon
BEH
0,03500
displacement
(mm)
0,03000
0,02500
0,02000
0,01500
0,01000
0,00500
0,00000
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
Conclusion:
Glass
scale
does
not
improve
ball
screw
Z
displacement
in
X
and
Z
directions
but
it
has
nearly
0,020
mm
less
displacement
than
ball
screw
in
Y
direction.
Displacement
of
Tool
(end
of
spindle
displacement)
of
course
is
the
same
for
ball
screw
and
for
glass
scale
in
X
direction
because
glass
scale
has
no
influence
in
this
direction,
but
not
in
Y
and
Z.
Displacement
for
ball
screw
is
bigger
than
for
glass
scale
in
0,011
mm
to
0,025
mm
when
spindle
speed
increase
from
8000
r.p.m.
to
20000
r.p.m.
respectively
for
Y
and
Z
directions.
Tool,
displacement
in
Y
during
work
cycle
with
iniaal
temperature
293K
at
posiaon
BEH
0,09000
0,08000
0,07000
0,06000
0,05000
0,04000
0,03000
0,02000
0,01000
0,00000
3600
7200
10800
14400
ame
(s)
displacement (mm)
glass scale YES glass scale NO
79
Tool,
displacement
in
Z
during
work
cycle
with
iniaal
temperature
293K
at
posiaon
BEH
0,16000
displacement
(mm)
0,14000
0,12000
0,10000
0,08000
0,06000
0,04000
0,02000
0,00000
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
Conclusion:
Glass
scale
does
not
improve
end
of
spindle
displacement
in
X
direction
but
has
nearly
0,020
mm
less
displacement
than
ball
screw
in
Y
and
Z
direction.
This
displacement
increase
when
we
raise
spindle
speed
rotation.
Displacement
for
Table
is
the
same
for
ball
screw
and
glass
scale
in
Y
and
Z
directions.
In
X
direction
displacement
for
glass
scale
is
practically
zero
but
there
is
a
big
displacement
for
ball
screw
from
0,013
mm
second
hour,
0,015
mm
third
hour
and
0,016
mm
forth
hour.
Table,
displacement
in
X
during
work
cycle
with
iniaal
temperature
293K
at
posiaon
BEH
0,02
displacement
(mm)
0,015
0,01
0,005
0
3600
-0,005
7200
10800
14400
ame
(s)
glass scale YES glass scale NO
Conclusion:
Glass
scale
does
not
improve
Table
displacement
in
Y
and
Z
directions
but
it
does
in
X
direction.
80
8.1.2
Analyses
of
work
cycle
with
initial
temperature
295K
at
BEH
Result
for
displacements
(mm)
during
work
cycle
with
initial
temperature
295K
at
position
BEH:
GLASS SCALE T=295K Position BEH time (s) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
dispacement (mm)
sensor ball screw X
ball screw Y
ball screw Z
tool
table
displacement direction X Y Z X Y Z X Y Z X Y Z X Y Z
3600 0,0230 0,0020 -0,0100 -0,0070 0,0260 -0,0510 0,0020 -0,0100 -0,0190 0,0100 0,0020 -0,0090 0,0120 -0,0080 -0,0130
7200 0,0280 0,0020 -0,0100 -0,0070 0,0430 -0,0510 0,0030 -0,0100 -0,0110 0,0160 -0,0040 -0,0180 0,0120 -0,0080 -0,0130
10800 0,0310 0,0020 -0,0100 -0,0060 0,0550 -0,0510 0,0080 -0,0060 0,0070 0,0280 0,0470 0,0830 0,0120 -0,0080 -0,0130
14400 0,0320 0,0020 -0,0090 -0,0060 0,0650 -0,0500 0,0100 -0,0060 0,0110 0,0530 0,0100 0,0100 0,0120 -0,0080 -0,0120
BALL SCREW
T=295K
Position BEH time (s) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
dispacement (mm)
sensor displacement direction ball screw X X Y Z ball screw Y X Y Z ball screw Z X Y Z tool X Y Z table X Y Z
3600 0,0230 0,0020 -0,0100 -0,0070 0,0260 -0,0510 0,0020 0,0020 -0,0210 0,0100 0,0150 -0,0008 0,0220 -0,0080 -0,0130
7200 0,0280 0,0020 -0,0100 -0,0070 0,0420 -0,0510 0,0030 0,0080 -0,0130 0,0160 0,0150 -0,0060 0,0260 -0,0080 -0,0130
10800 0,0300 0,0020 -0,0100 -0,0060 0,0540 -0,0510 0,0070 0,0160 0,0050 0,0300 0,0700 0,1050 0,0280 -0,0080 -0,0130
14400 0,0310 0,0020 -0,0090 -0,0060 0,0640 -0,0500 0,0100 0,0210 0,0100 0,0540 0,0370 0,0370 0,0290 -0,0080 -0,0120
Displacement of ball screw X: Same case than for 293K but displacements increase with temperature. Displacement of ball screw Y: Same case than for 293K. Displacement of ball screw Z: Same case than for 293K. The difference between displacement of ball screw and glass scale in Y direction continues being 0,020 mm but level of displacement increase with temperature.
81
Displacement of Tool: Same case than 293K. The difference between displacement of ball screw and glass scale in Y and Z directions continues being 0,020 mm.
Displacement
of
Table:
Same
case
than
for
293K
but
now,
even
if
the
difference
between
glass
scale
and
ball
screw
is
the
same,
displacement
for
glass
scale
is
medium
value
of
0,012
mm
in
X
direction.
Table,
displacement
in
X
during
work
cycle
with
iniaal
temperature
295K
at
posiaon
BEH
0,0350
displacement
(mm)
0,0300
0,0250
0,0200
0,0150
0,0100
0,0050
0,0000
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
8.1.3
Analyses
of
work
cycle
with
initial
temperature
298K
at
BEH
Result
for
displacements
(mm)
during
work
cycle
with
initial
temperature
298K
at
position
BEH:
GLASS SCALE T=298K Position BEH time (s) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
dispacement (mm)
sensor ball screw X
ball screw Y
ball screw Z
tool
table
displacement direction X Y Z X Y Z X Y Z X Y Z X Y Z
3600 0,0410 0,0040 -0,0260 -0,0180 0,0200 -0,1310 0,0030 -0,0310 -0,0800 0,0190 -0,0210 -0,0780 0,0310 -0,0210 -0,0360
7200 0,0460 0,0040 -0,0260 -0,0180 0,0350 -0,1300 0,0040 -0,0320 -0,0710 0,0240 -0,0270 -0,0830 0,0310 -0,0210 -0,0350
10800 0,0480 0,0040 -0,0250 -0,0180 0,0470 -0,1270 0,0080 -0,0280 -0,0520 0,0340 0,0220 0,0160 0,0300 -0,0210 -0,0340
14400 0,0490 0,0040 -0,0240 -0,0180 0,0560 -0,1240 0,0100 -0,0280 -0,0460 0,0570 -0,0150 -0,0540 0,0300 -0,0210 -0,0330
82
BALL SCREW T=298K Position BEH time (s) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
dispacement (mm)
sensor displacement direction ball screw X X Y Z ball screw Y X Y Z ball screw Z X Y Z tool X Y Z table X Y Z
3600 0,0410 0,0040 -0,0260 -0,0180 0,0200 -0,1310 0,0030 -0,0160 -0,0810 0,0190 -0,0050 -0,0690 0,0420 -0,0210 -0,0350
7200 0,0460 0,0040 -0,0260 -0,0180 0,0350 -0,1300 0,0040 -0,0100 -0,0720 0,0240 -0,0040 -0,0710 0,0470 -0,0210 -0,0340
10800 0,0480 0,0040 -0,0250 -0,0180 0,0470 -0,1270 0,0080 -0,0020 -0,0530 0,0350 0,0490 0,0380 0,0490 -0,0210 -0,0330
14400 0,0490 0,0040 -0,0240 -0,0180 0,0550 -0,1240 0,0100 0,0020 -0,0470 0,0580 0,0160 -0,0280 0,0490 -0,0210 -0,0330
Displacement of ball screw X: Same case than for 293K and 295K but displacements increase with temperature. Displacement of ball screw Y: Same case than for 293K and 295K. Displacement of ball screw Z: Same case than for 293K and 295K. The difference between displacement of ball screw and glass scale in Y direction continues being 0,020 mm but level of displacement increase with temperature. Displacement of Tool: Same case than for 293K and 295K. The difference between displacement of ball screw and glass scale in Y and Z directions continues being 0,020 mm. Displacement of Table: Same case than for 293K and 295K but 293K but now, even if the difference between glass scale and ball screw is the same, displacement for glass scale is medium value of 0,031 mm in X direction. 8.1.4 Conclusions at position BEH with different initial temperatures We can say as general conclusions at position BEH that: For ball screw X glass scale does not improves displacements in any direction and these displacements increase with initial temperature in all directions.
83
For
ball
screw
Y:
glass
scale
does
not
improve
displacement
in
any
direction.
For
ball
screw
Z:
glass
scale
improves
displacement
between
glass
scale
in
0,020
mm
in
Y
direction
but
level
of
displacement
increase
with
initial
temperature
ball
screw
Z,
displacement
in
Y
during
work
cycle
with
dierent
iniaal
temperatures
at
posiaon
BEH
0,02000
displacement
(mm)
0,01000
0,00000
-0,01000
-0,02000
-0,03000
-0,04000
ame
(s)
3600
7200
10800
14400
glass
scale
YES
293K
glass
scale
YES
295K
glass
scale
YES
298K
For
Tool:
glass
scale
improves
displacements
in
0,020
mm
in
Y
and
Z
directions
with
dependency
of
spindle
speed
rotation.
For
Table:
glass
scale
improves
displacement
in
X
direction
but
this
displacement
increase
with
initial
temperature.
Table,
displacement
in
X
during
work
cycle
with
dierent
iniaal
temperatures
at
posiaon
BEH
0,035
0,03
displacement
(mm)
0,025
0,02
0,015
0,01
0,005
0
-0,005
3600
7200
10800
ame
(s)
14400
glass
scale
YES
293K
glass
scale
YES
295K
glass
scale
YES
298K
84
8.2
Analyses
of
displacements
at
position
CFG
8.2.1
Analyses
of
work
cycle
with
initial
temperature
293K
at
CFG
Result
for
displacements
(mm)
during
work
cycle
with
initial
temperature
293K
at
position
CFG:
GLASS SCALE T=293K Position CFG time (s) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
dispacement (mm)
sensor ball screw X
ball screw Y
ball screw Z
tool
table
displacement direction X Y Z X Y Z X Y Z X Y Z X Y Z
3600 0,0200 0,0002 0,0009 0,0009 0,0400 0,0020 0,0020 0,0040 0,0230 0,0020 0,0140 0,0310 -0,0010 0,0006 0,0010
7200 0,0330 0,0003 0,0008 0,0010 0,0690 -0,0004 0,0030 0,0050 0,0330 0,0100 0,0090 0,0230 -0,0010 0,0004 0,0010
10800 0,0400 0,0004 0,0008 0,0010 0,0920 -0,0020 0,0090 0,0100 0,0490 0,0200 0,0520 0,1130 -0,0010 0,0003 0,0010
14400 0,0450 0,0005 0,0007 0,0010 0,1100 -0,0030 0,0120 0,0100 0,0530 0,0490 0,0180 0,0520 -0,0010 0,0003 0,0010
BALL SCREW T=293K Position CFG time (s) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
dispacement (mm)
sensor ball screw X
ball screw Y
ball screw Z
tool
table
displacement direction X Y Z X Y Z X Y Z X Y Z X Y Z
3600 0,0200 0,0001 0,0008 0,0009 0,0390 0,0020 0,0020 0,0050 0,0230 0,0020 0,0160 0,0500 0,0200 0,0006 0,0010
7200 0,0330 0,0003 0,0008 0,0010 0,0680 -0,0004 0,0030 0,0060 0,0330 0,0100 0,0110 0,0510 0,0320 0,0004 0,0010
10800 0,0400 0,0004 0,0007 0,0010 0,0910 -0,0020 0,0100 0,0120 0,0520 0,0210 0,0550 0,1630 0,0400 0,0004 0,0010
14400 0,0450 0,0004 0,0007 0,0010 0,1100 -0,0030 0,0120 0,0130 0,0540 0,0500 0,0230 0,1010 0,0440 0,0003 0,0010
Displacement of ball screw X: is practically the same for ball screw and for glass scale in X, Y and Z directions.
85
Conclusion:
Glass
scale
does
not
improve
ball
screw
X
displacement
in
X,
Y
and
Z
directions.
Displacement
of
ball
screw
Y:
is
practically
the
same
for
ball
screw
and
for
glass
scale
in
X,
Y
and
Z
directions.
Conclusion:
Glass
scale
does
not
improve
ball
screw
Y
displacement
in
X,
Y
and
Z
directions.
Displacement
of
ball
screw
Z:
is
practically
the
same
for
ball
screw
and
for
glass
scale
in
X,
Y
and
Z
directions.
Conclusion:
Glass
scale
does
not
improve
ball
screw
Y
displacement
in
X,
Y
and
Z
directions
Displacement
of
Tool:
is
practically
the
same
for
ball
screw
and
for
glass
scale
in
X
and
Y
direction
but
not
in
Z.
Displacement
for
ball
screw
is
bigger
than
for
glass
scale
in
practically
a
value
of
0,02
mm
to
0,05
mm
when
spindle
speed
increase
from
8000
r.p.m.
to
20000
r.p.m.
respectively
for
Z
direction.
Tool,
displacement
in
Z
during
work
cycle
with
iniaal
temperature
295K
at
posiaon
CFG
0,1400
0,1200
displacement
(mm)
0,1000
0,0800
0,0600
0,0400
0,0200
0,0000
-0,0200
3600
7200
10800
ame
(s)
14400
glass
scale
YES
glass
scale
NO
Conclusion:
Glass
scale
does
not
improve
end
of
spindle
displacement
in
X
and
Y
directions
but
has
nearly
0,020
mm
less
displacement
than
ball
screw
in
Z
direction.
This
displacement
increase
to
0,05
mm
when
we
raise
spindle
speed
rotation.
86
Displacement
of
Table:
is
the
same
for
ball
screw
and
glass
scale
in
Y
and
Z
directions.
In
X
direction
displacement
for
glass
scale
is
practically
cero
but
there
is
a
big
displacement
for
ball
screw
from
0,02
mm
first
hour,
0,032
mm
second
hour,
0,040
mm
third
hour
and
0,044
mm
fourth
hour.
Table,
displacement
in
X
during
work
cycle
with
iniaal
temperature
293K
at
posiaon
CFG
0,0500
0,0450
0,0400
0,0350
0,0300
0,0250
0,0200
0,0150
0,0100
0,0050
0,0000
-0,0050
displacement (mm)
glass scale YES glass scale NO
3600
7200 10800 ame (s)
14400
Conclusion:
Glass
scale
does
not
improve
Table
displacements
in
Y
and
Z
directions
but
it
does
in
X
direction.
8.2.2
Analyses
of
work
cycle
with
initial
temperature
295K
at
CFG
Result
for
displacements
(mm)
during
work
cycle
with
initial
temperature
295K
at
position
CFG:
GLASS SCALE T=295K Position CFG time (s) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
dispacement (mm)
sensor ball screw X
ball screw Y
ball screw Z
tool
table
displacement direction X Y Z X Y Z X Y Z X Y Z X Y Z
3600 0,0330 0,0010 -0,0100 -0,0070 0,0360 -0,0520 0,0020 -0,0150 -0,0110 0,0100 -0,0030 -0,0050 0,0170 -0,0080 -0,0100
7200 0,0450 0,0010 -0,0100 -0,0060 0,0640 -0,0530 0,0030 -0,0150 -0,0004 0,0160 -0,0080 -0,0110 0,0170 -0,0080 -0,0090
10800 0,0520 0,0010 -0,0100 -0,0060 0,0870 -0,0530 0,0090 -0,0100 0,0160 0,0250 0,0350 0,0790 0,0170 -0,0080 -0,0090
14400 0,0570 0,0010 -0,0100 -0,0060 0,1050 -0,0530 0,0120 -0,0100 0,0210 0,0530 0,0009 0,0190 0,0160 -0,0080 -0,0080
87
BALL SCREW T=295K Position CFG time (s) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
dispacement (mm)
sensor ball screw X
ball screw Y
ball screw Z
tool
displacement direction X Y Z X Y Z X Y Z X Y X Y Z
table
3600 0,0320 0,0010 -0,0100 -0,0070 0,0350 -0,0520 0,0020 -0,0150 -0,0110 0,0100 -0,0020 0,0150 0,0410 -0,0080 -0,0100
7200 0,0450 0,0010 -0,0100 -0,0060 0,0640 -0,0530 0,0030 -0,0140 -0,0006 0,0160 -0,0050 0,0180 0,0530 -0,0080 -0,0090
10800 0,0520 0,0020 -0,0100 -0,0060 0,0860 -0,0530 0,0090 -0,0080 0,0190 0,0250 0,0380 0,1280 0,0610 -0,0080 -0,0090
14400 0,0570 0,0020 -0,0100 -0,0060 0,1050 -0,0530 0,0120 -0,0070 0,0220 0,0530 0,0060 0,0660 0,0650 -0,0080 -0,0090
Displacement of ball screw X: same case than for 293K. Displacement of ball screw Y: same case than for 293K. Displacement of ball screw Z: same case than for 293K. Displacement of Tool: Same case than for 293K. The difference between displacement of ball screw and glass scale in Z direction continues being 0,020 mm and increase to 0,05 mm when we raise spindle speed rotation.
Displacement
of
Table:
Same
case
than
for
293K,
but
now,
even
if
the
difference
between
glass
scale
and
ball
screw
is
the
same,
displacement
for
glass
scale
is
medium
value
of
0,017
mm
in
X
direction.
Table,
displacement
in
X
during
work
cycle
with
iniaal
temperature
295K
at
posiaon
CFG
0,0700
displacement
(mm)
0,0600
0,0500
0,0400
0,0300
0,0200
0,0100
0,0000
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
88
8.2.3
Analyses
of
work
cycle
with
initial
temperature
298K
at
CFG
Result
for
displacements
(mm)
during
work
cycle
with
initial
temperature
298K
at
position
CFG:
GLASS SCALE T=298K Positions CFG time (s) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
dispacement (mm)
sensor ball screw X
ball screw Y
ball screw Z
tool
table
displacement direction X Y Z X Y Z X Y Z X Y Z X Y Z
3600 0,0510 0,0030 -0,0270 -0,0180 0,0290 -0,1320 0,0020 -0,0440 -0,0620 0,0210 -0,0280 -0,0580 0,0440 -0,0210 -0,0260
7200 0,0630 0,0030 -0,0260 -0,0180 0,0570 -0,1310 0,0030 -0,0440 -0,0500 0,0250 -0,0320 -0,0600 0,0440 -0,0210 -0,0240
10800 0,0700 0,0030 -0,0260 -0,0180 0,0790 -0,1290 0,0080 -0,0390 -0,0330 0,0320 0,0090 0,0280 0,0430 -0,0210 -0,0240
14400 0,0740 0,0030 -0,0250 -0,0180 0,0970 -0,1270 0,0100 -0,0390 -0,0270 0,0570 -0,0240 -0,0310 0,0430 -0,0200 -0,0230
BALL SCREW T=298K Position CFG time (s) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
dispacement (mm)
sensor ball screw X
ball screw Y
ball screw Z
tool
table
displacement direction X Y Z X Y Z X Y Z X Y Z X Y Z
3600 0,0510 0,0030 -0,0270 -0,0180 0,0290 -0,1320 0,0020 -0,0450 -0,0620 0,0210 -0,0280 -0,0380 0,0730 -0,0210 -0,0260
7200 0,0630 0,0030 -0,0260 -0,0180 0,0570 -0,1310 0,0030 -0,0440 -0,0500 0,0250 -0,0300 -0,0320 0,0850 -0,0210 -0,0240
10800 0,0700 0,0030 -0,0260 -0,0180 0,0790 -0,1290 0,0080 -0,0380 -0,0310 0,0320 0,0120 0,0760 0,0930 -0,0210 -0,0240
14400 0,0740 0,0030 -0,0250 -0,0180 0,0970 -0,1270 0,0100 -0,0360 -0,0260 0,0580 -0,0200 0,0150 0,0970 -0,0200 -0,0230
Displacement of ball screw X: Displacement of ball screw X: same case than for 293K and 295K. Displacement of ball screw Y: same case than for 293K and 295K. Displacement of ball screw Z: Displacement of ball screw Z: same case than for 293K and 295K.
89
Displacement of Tool: Same case than for 293K and 295K. The difference between displacement of ball screw and glass scale in Z direction continues being 0,020 mm and increase to 0,05 mm when we raise spindle speed rotation.
Displacement of Table: Same case than for 293K and 295K, but now, even if the difference between glass scale and ball screw is the same, displacement for glass scale is medium value of 0,044 mm in X direction.
8.2.4
Conclusions
at
position
CFG
with
different
initial
temperatures
We
can
say
as
general
conclusions
at
position
BEH
that:
For
ball
screw
X
glass
scale
does
not
improve
displacements
in
any
direction
and
these
displacements
increase
with
initial
temperature
in
all
directions.
For
ball
screw
Y:
glass
scale
does
not
improve
displacement
in
any
direction.
For
ball
screw
Z:
glass
scale
improves
displacement
between
glass
scale
in
0,020
mm
in
Y
direction
but
level
of
this
displacement
increase
with
initial
temperature.
ball
screw
Z,
displacement
in
Y
during
work
cycle
with
dierent
iniaal
temperatures
at
posiaon
CFG
0,0200
0,0100
displacement
(mm)
0,0000
-0,0100
-0,0200
-0,0300
-0,0400
-0,0500
ame
(s)
3600
7200
10800
14400
glass
scale
YES
293K
glass
scale
YES
295K
glass
scale
YES
298K
dependency of spindle speed rotation.
For Tool: glass scale improves displacements in 0,020 mm in Z direction with
90
For
Table:
glass
scale
improves
displacement
in
X
direction
but
this
displacement
increase
with
initial
temperature.
Table,
displacement
in
X
during
work
cycle
with
dierent
iniaal
temperatures
at
posiaon
CFG
0,0500
displacement
(mm)
0,0400
0,0300
0,0200
0,0100
0,0000
-0,0100
3600
7200
10800
14400
ame
(s)
glass
scale
YES
293K
glass
scale
YES
295K
glass
scale
YES
298K
8.3
Conclusions
drawn
from
computing
analysis
Attending
to
conclusions
draw
from
position
BEH
and
position
CFG
we
are
looking
in
this
section
for
common
or
different
aspects
of
behavior
of
machine
centre
in
function
of
position
of
headstock
and
table.
For
ball
screw
X:
glass
scale
of
course
does
not
improve
displacements
in
any
direction.
This
is
useful
to
probe
that
both
models,
with
and
without
glass
scale,
are
well
done.
These
displacements
increase
with
initial
temperature
in
all
directions.
If
ball
screw
X
is
in
point
G,
then
LG=Lmax
(where
Lmax
is
measured
from
the
motor
to
the
nut)
and
in
order
to
! = !"!
end
of
spindle
displacements
in
X
direction
are
maximum
and
double
than
in
point
H
because
LH=LG/2
For
ball
screw
Y:
glass
scale
of
course
does
not
improve
displacements
in
any
directions
and
has
no
dependency
on
position.
Is
important
here
to
notice
that
displacements
in
Y
direction
there
are
for
each
point
in
the
range
of
0,030
mm
to
0,110
mm.
These
are
quite
big
displacements
that
did
not
been
reduced
with
the
glass
scale.
91
For ball screw Z: glass scale improves displacement in 0,020 mm in Y direction but level of displacement increase with initial temperature and has no dependency of position but increase in a constant value of 0,020 mm from 293K to 295K and 0,020 mm from 295K to 298K so it is possible to correct these displacements. For Tool: glass scale improves displacement depending on position and spindle speed rotation. For position BEH glass scale improves displacement in Y and Z direction but for position CFG only improves in Z direction. This means that in positions at middle point of glass scale, L0 (in case of glass scale we measure L from the middle point to the reading head) displacements are smaller in order to ! = !"! For Table: glass scale improves displacement only in X direction and with dependency on ambient temperature which makes level of displacement increase in constant values so it is possible to correct these displacements. In general terms, a glass scale at X direction (the one with the reading head fix to the table) improves displacements of the table in X direction and although level of these displacements increase with initial temperature, it is possible to compensate them because increases in constant values. There is a big displacement in the range of 0,030 mm to 0,110 mm for ball screw Y in Y direction with or without glass scale with any dependency of position. Glass scale at the headstock improves displacement of headstock always in Z direction with dependency of spindle speed rotation and in Y direction only when headstock is at the middle of glass scale.
92
9.
Conclusions
leading
to
improve
of
machining
centre
design
In
order
to
conclusions
on
section
8.3
we
know
that
glass
scale
improves
displacements
when
heat
fluxes
do
not
increase
too
much
temperature
of
the
glass
scale.
This
happens
with
the
glass
scale
on
X
direction,
the
one
in
the
base
of
the
machine
centre
and
with
the
reading
head
fixed
to
the
table.
This
glass
scale
is
only
influenced
by
power
losses
of
ball
screw
X.
This
power
losses
are
not
too
big
so
the
thermal
deformation
of
the
glass
scale
is
small,
in
other
words,
glass
scale
at
the
table
does
not
increase
its
own
temperature
too
much.
When
this
happens
glass
scale
improves
displacements
like
glass
scale
at
the
table
with
table
displacements
in
X
direction.
According
to
this,
we
know
that
it
is
important
that
glass
scale
do
not
increase
it
own
temperature
during
thermal
deformation.
Power
losses
at
the
headstock
are
big
and
produces
hit
fluxes
that
increase
temperature
of
glass
scale
on
Z
direction.
One
solution
to
avoid
this
problem
is
to
isolate
the
glass
scale
at
the
head
stock.
This
can
be
made
by
using
low
thermal
conductivity
materials
between
the
aluminum
body
of
the
linear
encoder
and
the
special
shapes
to
fix
it
to
the
body
of
the
machine
tool.
Doing
this,
heat
fluxes
from
power
losses
at
the
headstock
will
increase
temperature
of
glass
scale
in
Z
direction
but
not
too
much
so
thermal
deformation
of
the
glass
scale
will
be
smaller.
Position
of
glass
scale
is
also
important.
As
we
see
after
computation,
when
reading
head
is
at
middle
point
of
glass
scale
(the
point
that
is
fixed
as
fastened
connection
property)
displacements
are
smaller.
If
we
change
position
of
glass
scale
so
the
fixed
point
will
be
closer
to
end
of
spindle,
displacements
at
this
point
will
be
better,
but
it
will
be
worst
in
the
middle
and
in
the
other
side
of
the
spindle.
Better
solution
is
to
keep
glass
scale
positions
as
in
our
models
so
displacements
will
be
smaller
when
table
and
headstocks
are
at
position
BEH.
93
10. Attachments Here are shown all the results of computation.
GLASS SCALE T=293K Position BEH time (s) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
dispacement (mm)
sensor ball screw X
ball screw Y
ball screw Z
tool
table
displacement direction X Y Z X Y Z X Y Z X Y Z X Y Z
3600 0,0120 0,0003 0,0009 0,0009 0,0300 0,0020 0,0020 0,0040 0,0210 0,0030 0,0170 0,0370 -0,0010 0,0006 0,0010
7200 0,0170 0,0005 0,0009 0,0010 0,0480 0,0010 0,0030 0,0040 0,0290 0,0110 0,0110 0,0250 -0,0009 0,0005 0,0010
10800 0,0190 0,0005 0,0008 0,0010 0,0600 0,0001 0,0080 0,0090 0,0470 0,0240 0,0630 0,1270 -0,0008 0,0004 0,0010
14400 0,0200 0,0005 0,0008 0,0010 0,0700 -0,0006 0,0110 0,0090 0,0500 0,0500 0,0260 0,0530 -0,0007 0,0003 0,0010
GLASS SCALE T=295K Position BEH time (s) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
dispacement (mm)
sensor ball screw X
ball screw Y
ball screw Z
tool
table
displacement direction X Y Z X Y Z X Y Z X Y Z X Y Z
3600 0,0230 0,0020 -0,0100 -0,0070 0,0260 -0,0510 0,0020 -0,0100 -0,0190 0,0100 0,0020 -0,0090 0,0120 -0,0080 -0,0130
7200 0,0280 0,0020 -0,0100 -0,0070 0,0430 -0,0510 0,0030 -0,0100 -0,0110 0,0160 -0,0040 -0,0180 0,0120 -0,0080 -0,0130
10800 0,0310 0,0020 -0,0100 -0,0060 0,0550 -0,0510 0,0080 -0,0060 0,0070 0,0280 0,0470 0,0830 0,0120 -0,0080 -0,0130
14400 0,0320 0,0020 -0,0090 -0,0060 0,0650 -0,0500 0,0100 -0,0060 0,0110 0,0530 0,0100 0,0100 0,0120 -0,0080 -0,0120
94
GLASS SCALE
T=298K
Position BEH time (s) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
dispacement (mm)
sensor ball screw X
ball screw Y
ball screw Z
tool
table
displacement direction X Y Z X Y Z X Y Z X Y Z X Y Z
3600 0,0410 0,0040 -0,0260 -0,0180 0,0200 -0,1310 0,0030 -0,0310 -0,0800 0,0190 -0,0210 -0,0780 0,0310 -0,0210 -0,0360
7200 0,0460 0,0040 -0,0260 -0,0180 0,0350 -0,1300 0,0040 -0,0320 -0,0710 0,0240 -0,0270 -0,0830 0,0310 -0,0210 -0,0350
10800 0,0480 0,0040 -0,0250 -0,0180 0,0470 -0,1270 0,0080 -0,0280 -0,0520 0,0340 0,0220 0,0160 0,0300 -0,0210 -0,0340
14400 0,0490 0,0040 -0,0240 -0,0180 0,0560 -0,1240 0,0100 -0,0280 -0,0460 0,0570 -0,0150 -0,0540 0,0300 -0,0210 -0,0330
GLASS SCALE T=293K Position CFG time (s) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
dispacement (mm)
sensor ball screw X
ball screw Y
ball screw Z
tool
table
displacement direction X Y Z X Y Z X Y Z X Y Z X Y Z
3600 0,0200 0,0002 0,0009 0,0009 0,0400 0,0020 0,0020 0,0040 0,0230 0,0020 0,0140 0,0310 -0,0010 0,0006 0,0010
7200 0,0330 0,0003 0,0008 0,0010 0,0690 -0,0004 0,0030 0,0050 0,0330 0,0100 0,0090 0,0230 -0,0010 0,0004 0,0010
10800 0,0400 0,0004 0,0008 0,0010 0,0920 -0,0020 0,0090 0,0100 0,0490 0,0200 0,0520 0,1130 -0,0010 0,0003 0,0010
14400 0,0450 0,0005 0,0007 0,0010 0,1100 -0,0030 0,0120 0,0100 0,0530 0,0490 0,0180 0,0520 -0,0010 0,0003 0,0010
GLASS SCALE T=295K Position CFG time (s) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
dispacement (mm)
sensor ball screw X
ball screw Y
ball screw Z
tool
table
displacement direction X Y Z X Y Z X Y Z X Y Z X Y Z
3600 0,0330 0,0010 -0,0100 -0,0070 0,0360 -0,0520 0,0020 -0,0150 -0,0110 0,0100 -0,0030 -0,0050 0,0170 -0,0080 -0,0100
7200 0,0450 0,0010 -0,0100 -0,0060 0,0640 -0,0530 0,0030 -0,0150 -0,0004 0,0160 -0,0080 -0,0110 0,0170 -0,0080 -0,0090
10800 0,0520 0,0010 -0,0100 -0,0060 0,0870 -0,0530 0,0090 -0,0100 0,0160 0,0250 0,0350 0,0790 0,0170 -0,0080 -0,0090
14400 0,0570 0,0010 -0,0100 -0,0060 0,1050 -0,0530 0,0120 -0,0100 0,0210 0,0530 0,0009 0,0190 0,0160 -0,0080 -0,0080
95
GLASS SCALE
T=298K
Positions CFG time (s) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
dispacement (mm)
sensor ball screw X
ball screw Y
ball screw Z
tool
table
displacement direction X Y Z X Y Z X Y Z X Y Z X Y Z
3600 0,0510 0,0030 -0,0270 -0,0180 0,0290 -0,1320 0,0020 -0,0440 -0,0620 0,0210 -0,0280 -0,0580 0,0440 -0,0210 -0,0260
7200 0,0630 0,0030 -0,0260 -0,0180 0,0570 -0,1310 0,0030 -0,0440 -0,0500 0,0250 -0,0320 -0,0600 0,0440 -0,0210 -0,0240
10800 0,0700 0,0030 -0,0260 -0,0180 0,0790 -0,1290 0,0080 -0,0390 -0,0330 0,0320 0,0090 0,0280 0,0430 -0,0210 -0,0240
14400 0,0740 0,0030 -0,0250 -0,0180 0,0970 -0,1270 0,0100 -0,0390 -0,0270 0,0570 -0,0240 -0,0310 0,0430 -0,0200 -0,0230
BALL SCREW T=293K Position BEH time (s) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
dispacement (mm)
sensor displacement direction ball screw X X Y Z ball screw Y X Y Z ball screw Z X Y Z tool X Y Z table X Y Z
3600 0,0110 0,0003 0,0009 0,0009 0,0300 0,0020 0,0010 0,0140 0,0200 0,0040 0,0280 0,0450 0,0080 0,0006 0,0010
7200 0,0160 0,0004 0,0008 0,0010 0,0470 0,0009 0,0030 0,0200 0,0270 0,0110 0,0280 0,0380 0,0130 0,0005 0,0010
10800 0,0190 0,0004 0,0008 0,0010 0,0600 0,0003 0,0070 0,0280 0,0450 0,0260 0,0830 0,1500 0,0150 0,0004 0,0010
14400 0,0200 0,0005 0,0007 0,0010 0,0700 -0,0008 0,0110 0,0330 0,0490 0,0510 0,0510 0,0810 0,0160 0,0003 0,0010
BALL SCREW T=295K Position BEH time (s) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
dispacement (mm)
sensor displacement direction ball screw X X Y Z ball screw Y X Y Z ball screw Z X Y Z tool X Y Z table X Y Z
3600 0,0230 0,0020 -0,0100 -0,0070 0,0260 -0,0510 0,0020 0,0020 -0,0210 0,0100 0,0150 -0,0008 0,0220 -0,0080 -0,0130
7200 0,0280 0,0020 -0,0100 -0,0070 0,0420 -0,0510 0,0030 0,0080 -0,0130 0,0160 0,0150 -0,0060 0,0260 -0,0080 -0,0130
10800 0,0300 0,0020 -0,0100 -0,0060 0,0540 -0,0510 0,0070 0,0160 0,0050 0,0300 0,0700 0,1050 0,0280 -0,0080 -0,0130
14400 0,0310 0,0020 -0,0090 -0,0060 0,0640 -0,0500 0,0100 0,0210 0,0100 0,0540 0,0370 0,0370 0,0290 -0,0080 -0,0120
96
BALL SCREW
T=298K
Position BEH time (s) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
dispacement (mm)
sensor displacement direction ball screw X X Y Z ball screw Y X Y Z ball screw Z X Y Z tool X Y Z table X Y Z
3600 0,0410 0,0040 -0,0260 -0,0180 0,0200 -0,1310 0,0030 -0,0160 -0,0810 0,0190 -0,0050 -0,0690 0,0420 -0,0210 -0,0350
7200 0,0460 0,0040 -0,0260 -0,0180 0,0350 -0,1300 0,0040 -0,0100 -0,0720 0,0240 -0,0040 -0,0710 0,0470 -0,0210 -0,0340
10800 0,0480 0,0040 -0,0250 -0,0180 0,0470 -0,1270 0,0080 -0,0020 -0,0530 0,0350 0,0490 0,0380 0,0490 -0,0210 -0,0330
14400 0,0490 0,0040 -0,0240 -0,0180 0,0550 -0,1240 0,0100 0,0020 -0,0470 0,0580 0,0160 -0,0280 0,0490 -0,0210 -0,0330
BALL SCREW T=293K Position CFG time (s) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
dispacement (mm)
sensor ball screw X
ball screw Y
ball screw Z
tool
table
displacement direction X Y Z X Y Z X Y Z X Y Z X Y Z
3600 0,0200 0,0001 0,0008 0,0009 0,0390 0,0020 0,0020 0,0050 0,0230 0,0020 0,0160 0,0500 0,0200 0,0006 0,0010
7200 0,0330 0,0003 0,0008 0,0010 0,0680 -0,0004 0,0030 0,0060 0,0330 0,0100 0,0110 0,0510 0,0320 0,0004 0,0010
10800 0,0400 0,0004 0,0007 0,0010 0,0910 -0,0020 0,0100 0,0120 0,0520 0,0210 0,0550 0,1630 0,0400 0,0004 0,0010
14400 0,0450 0,0004 0,0007 0,0010 0,1100 -0,0030 0,0120 0,0130 0,0540 0,0500 0,0230 0,1010 0,0440 0,0003 0,0010
BALL SCREW T=295K Position CFG time (s) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
dispacement (mm)
sensor ball screw X
ball screw Y
ball screw Z
tool
displacement direction X Y Z X Y Z X Y Z X Y X Y Z
table
3600 0,0320 0,0010 -0,0100 -0,0070 0,0350 -0,0520 0,0020 -0,0150 -0,0110 0,0100 -0,0020 0,0150 0,0410 -0,0080 -0,0100
7200 0,0450 0,0010 -0,0100 -0,0060 0,0640 -0,0530 0,0030 -0,0140 -0,0006 0,0160 -0,0050 0,0180 0,0530 -0,0080 -0,0090
10800 0,0520 0,0020 -0,0100 -0,0060 0,0860 -0,0530 0,0090 -0,0080 0,0190 0,0250 0,0380 0,1280 0,0610 -0,0080 -0,0090
14400 0,0570 0,0020 -0,0100 -0,0060 0,1050 -0,0530 0,0120 -0,0070 0,0220 0,0530 0,0060 0,0660 0,0650 -0,0080 -0,0090
97
BALL SCREW
T=298K
Position CFG time (s) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
dispacement (mm)
sensor ball screw X
ball screw Y
ball screw Z
tool
table
displacement direction X Y Z X Y Z X Y Z X Y Z X Y Z
3600 0,0510 0,0030 -0,0270 -0,0180 0,0290 -0,1320 0,0020 -0,0450 -0,0620 0,0210 -0,0280 -0,0380 0,0730 -0,0210 -0,0260
7200 0,0630 0,0030 -0,0260 -0,0180 0,0570 -0,1310 0,0030 -0,0440 -0,0500 0,0250 -0,0300 -0,0320 0,0850 -0,0210 -0,0240
10800 0,0700 0,0030 -0,0260 -0,0180 0,0790 -0,1290 0,0080 -0,0380 -0,0310 0,0320 0,0120 0,0760 0,0930 -0,0210 -0,0240
14400 0,0740 0,0030 -0,0250 -0,0180 0,0970 -0,1270 0,0100 -0,0360 -0,0260 0,0580 -0,0200 0,0150 0,0970 -0,0200 -0,0230
98
ball
screw
X,
displacement
in
X
during
work
cycle
with
iniaal
temperature
295K
at
posiaon
BEH
0,0350
0,0300
0,0250
0,0200
0,0150
0,0100
0,0050
0,0000
3600
7200
10800
14400
ame
(s)
displacement
(mm)
glass scale YES glass scale NO
ball
screw
X,
displacement
in
Y
during
work
cycle
with
iniaal
temperature
295K
at
posiaon
BEH
0,0025
displacement
(mm)
0,0020
0,0015
0,0010
0,0005
0,0000
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
99
ball
screw
X,
displacement
in
Z
during
work
cycle
with
iniaal
temperature
295K
at
posiaon
BEH
-0,0085
displacement
(mm)
3600
-0,0090
-0,0095
-0,0100
-0,0105
glass
scale
YES
glass
scale
NO
7200
10800
14400
ame (s)
ball
screw
X,
displacement
in
X
during
work
cycle
with
iniaal
temperature
298K
at
posiaon
BEH
0,0500
0,0480
0,0460
0,0440
0,0420
0,0400
0,0380
0,0360
3600
7200
10800
14400
ame
(s)
displacement
(mm)
glass scale YES glass scale NO
ball
screw
X,
displacement
in
Y
during
work
cycle
with
iniaal
temperature
298K
at
posiaon
BEH
0,0050
displacement
(mm)
0,0040
0,0030
0,0020
0,0010
0,0000
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
100
ball
screw
X,
displacement
in
Z
during
work
cycle
with
iniaal
temperature
298K
at
posiaon
BEH
-0,0230
displacement
(mm)
-0,0235
-0,0240
-0,0245
-0,0250
-0,0255
-0,0260
-0,0265
ame
(s)
glass
scale
YES
glass
scale
NO
3600
7200
10800
14400
ball
screw
X,
displacement
in
X
during
work
cycle
with
iniaal
temperature
293K
at
posiaon
CFG
0,0500
displacement
(mm)
0,0400
0,0300
0,0200
0,0100
0,0000
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
ball
screw
X,
displacement
in
Y
during
work
cycle
with
iniaal
temperature
293K
at
posiaon
CFG
0,0005
displacement
(mm)
0,0004
0,0003
0,0002
0,0001
0,0000
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
101
ball
screw
X,
displacement
in
Z
during
work
cycle
with
iniaal
temperature
293K
at
posiaon
CFG
0,0010
displacement
(mm)
0,0008
0,0006
0,0004
0,0002
0,0000
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
ball
screw
X,
displacement
in
X
during
work
cycle
with
iniaal
temperature
295K
at
posiaon
CFG
0,0600
displacement
(mm)
0,0500
0,0400
0,0300
0,0200
0,0100
0,0000
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
ball
screw
X,
displacement
in
Y
during
work
cycle
with
iniaal
temperature
295K
at
posiaon
CFG
0,0025
displacement
(mm)
0,0020
0,0015
0,0010
0,0005
0,0000
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
102
ball
screw
X,
displacement
in
Z
during
work
cycle
with
iniaal
temperature
295K
at
posiaon
CFG
0,0000
displacement
(mm)
-0,0020
-0,0040
-0,0060
-0,0080
-0,0100
-0,0120
ame
(s)
glass
scale
YES
glass
scale
NO
3600
7200
10800
14400
ball
screw
X,
displacement
in
X
during
work
cycle
with
iniaal
temperature
298K
at
posiaon
CFG
0,0800
0,0700
0,0600
0,0500
0,0400
0,0300
0,0200
0,0100
0,0000
3600
7200
10800
14400
ame
(s)
displacement
(mm)
glass scale YES glass scale NO
ball
screw
X,
displacement
in
Y
during
work
cycle
with
iniaal
temperature
298K
at
posiaon
CFG
0,0035
0,0030
0,0025
0,0020
0,0015
0,0010
0,0005
0,0000
3600
7200
10800
14400
ame
(s)
displacement
(mm)
glass scale YES glass scale NO
103
ball
screw
X,
displacement
in
Z
during
work
cycle
with
iniaal
temperature
298K
at
posiaon
CFG
-0,0240
displacement
(mm)
-0,0245
-0,0250
-0,0255
-0,0260
-0,0265
-0,0270
-0,0275
ame
(s)
glass
scale
YES
glass
scale
NO
3600
7200
10800
14400
ball
screw
Y,
displacement
in
X
during
work
cycle
with
iniaal
temperature
293K
at
posiaon
BEH
0,0010
0,0010
0,0010
0,0010
0,0009
0,0009
0,0009
0,0009
3600
7200
10800
14400
ame(s)
displacement
(mm)
ball screw YES ball screw NO
ball
screw
Y,
displacement
in
Y
during
work
cycle
with
iniaal
temperature
293K
at
posiaon
BEH
0,0800
0,0700
0,0600
0,0500
0,0400
0,0300
0,0200
0,0100
0,0000
3600
7200
10800
14400
ame
(s)
displacement
(mm)
glass scale YES glass scale NO
104
ball
screw
Y,
displacement
in
Z
during
work
cylce
with
iniaal
temperature
293K
at
posiaon
BEH
0,0025
displacement
(mm)
0,0020
0,0015
0,0010
0,0005
0,0000
-0,0005
-0,0010
3600
7200
10800
14400
glass
scale
YES
glass
scale
NO
ame (s)
ball
screw
Y,
displacement
in
X
during
work
cycle
with
iniaal
temperature
295K
at
posiaon
BEH
-0,0054
-0,0056
-0,0058
-0,0060
-0,0062
-0,0064
-0,0066
-0,0068
-0,0070
-0,0072
3600
7200
10800
14400
displacement (mm)
glass scale YES glass scale NO
ame(s)
ball
screw
Y,
displacement
in
Y
during
work
cycle
with
iniaal
temperature
295K
at
posiaon
BEH
0,0700
0,0600
0,0500
0,0400
0,0300
0,0200
0,0100
0,0000
3600
7200
10800
14400
ame
(s)
displacement
(mm)
glass scale YES glass scale NO
105
ball
screw
Y,
displacement
in
Z
during
work
cylce
with
iniaal
temperature
295K
at
posiaon
BEH
-0,0494
-0,0496
-0,0498
-0,0500
-0,0502
-0,0504
-0,0506
-0,0508
-0,0510
-0,0512
3600
7200
10800
14400
displacement (mm)
glass scale YES glass scale NO
ame (s)
ball
screw
Y,
displacement
in
X
during
work
cycle
with
iniaal
temperature
298K
at
posiaon
BEH
0,0000
displacement
(mm)
3600
-0,0050
-0,0100
-0,0150
-0,0200
glass
scale
YES
glass
scale
NO
7200
10800
14400
ame(s)
ball
screw
Y,
displacement
in
Y
during
work
cycle
with
iniaal
temperature
298K
at
posiaon
BEH
0,0600
displacement
(mm)
0,0500
0,0400
0,0300
0,0200
0,0100
0,0000
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
106
ball
screw
Y,
displacement
in
Z
during
work
cylce
with
iniaal
temperature
298K
at
posiaon
BEH
-0,1200
displacement
(mm)
-0,1220
-0,1240
-0,1260
-0,1280
-0,1300
-0,1320
ame
(s)
glass
scale
YES
glass
scale
NO
3600
7200
10800
14400
ball
screw
Y,
displacement
in
X
during
work
cycle
with
iniaal
temperature
293K
at
posiaon
CFG
0,0011
displacement
(mm)
0,0010
0,0010
0,0009
0,0009
0,0008
3600
7200
10800
14400
ame(s)
ball
screw
YES
ball
screw
NO
ball
screw
Y,
displacement
in
Y
during
work
cycle
with
iniaal
temperature
293K
at
posiaon
CFG
0,1200
displacement
(mm)
0,1000
0,0800
0,0600
0,0400
0,0200
0,0000
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
107
ball
screw
Y,
displacement
in
Z
during
work
cylce
with
iniaal
temperature
293K
at
posiaon
CFG
0,0030
displacement
(mm)
0,0020
0,0010
0,0000
-0,0010
-0,0020
-0,0030
-0,0040
ame
(s)
3600
7200
10800
14400
glass
scale
YES
glass
scale
NO
ball
screw
Y,
displacement
in
X
during
work
cycle
with
iniaal
temperature
295K
at
posiaon
CFG
-0,0054
-0,0056
-0,0058
-0,0060
-0,0062
-0,0064
-0,0066
-0,0068
-0,0070
-0,0072
3600
7200
10800
14400
displacement (mm)
glass scale YES glass scale NO
ame(s)
ball
screw
Y,
displacement
in
Y
during
work
cycle
with
iniaal
temperature
295K
at
posiaon
CFG
0,1200
displacement
(mm)
0,1000
0,0800
0,0600
0,0400
0,0200
0,0000
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
108
ball
screw
Y,
displacement
in
Z
during
work
cylce
with
iniaal
temperature
295K
at
posiaon
CFG
-0,0514
-0,0516
-0,0518
-0,0520
-0,0522
-0,0524
-0,0526
-0,0528
-0,0530
-0,0532
3600
7200
10800
14400
displacement (mm)
glass scale YES glass scale NO
ame (s)
ball
screw
Y,
displacement
in
X
during
work
cycle
with
iniaal
temperature
298K
at
posiaon
CFG
0,0000
displacement
(mm)
3600
-0,0050
-0,0100
-0,0150
-0,0200
glass
scale
YES
glass
scale
NO
7200
10800
14400
ame(s)
ball
screw
Y,
displacement
in
Y
during
work
cycle
with
iniaal
temperature
298K
at
posiaon
CFG
0,1200
displacement
(mm)
0,1000
0,0800
0,0600
0,0400
0,0200
0,0000
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
109
ball
screw
Y,
displacement
in
Z
during
work
cylce
with
iniaal
temperature
298K
at
posiaon
CFG
-0,1240
-0,1250
-0,1260
-0,1270
-0,1280
-0,1290
-0,1300
-0,1310
-0,1320
-0,1330
3600
7200
10800
14400
displacement (mm)
glass scale YES glass scale NO
ame (s)
ball
screw
Z,
displacement
in
X
during
work
cycle
with
iniaal
temperature
293K
at
posiaon
BEH
0,01200
displacement
(mm)
0,01000
0,00800
0,00600
0,00400
0,00200
0,00000
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
ball
screw
Z,
displacement
in
Y
during
work
cycle
with
iniaal
temperature
293K
at
posiaon
BEH
0,03500
0,03000
0,02500
0,02000
0,01500
0,01000
0,00500
0,00000
3600
7200
10800
14400
ame
(s)
displacement
(mm)
glass scale YES glass scale NO
110
ball
screw
Z,
displacement
in
Z
during
work
cycle
with
iniaal
temperature
293K
at
posiaon
BEH
0,06000
displacement
(mm)
0,05000
0,04000
0,03000
0,02000
0,01000
0,00000
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
ball
screw
Z,
displacement
in
X
during
work
cycle
with
iniaal
temperature
295K
at
posiaon
BEH
0,0120
displacement
(mm)
0,0100
0,0080
0,0060
0,0040
0,0020
0,0000
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
ball
screw
Z,
displacement
in
Y
during
work
cycle
with
iniaal
temperature
295K
at
posiaon
BEH
0,0250
0,0200
0,0150
0,0100
0,0050
0,0000
-0,0050
-0,0100
-0,0150
displacement (mm)
glass scale YES 3600 7200 10800 14400 glass scale NO
ame (s)
111
ball
screw
Z,
displacement
in
Z
during
work
cycle
with
iniaal
temperature
295K
at
posiaon
BEH
0,0150
0,0100
0,0050
0,0000
-0,0050
-0,0100
-0,0150
-0,0200
-0,0250
displacement (mm)
3600
7200
10800
14400
glass scale YES glass scale NO
ame (s)
ball
screw
Z,
displacement
in
X
during
work
cycle
with
iniaal
temperature
298K
at
posiaon
BEH
0,0120
displacement
(mm)
0,0100
0,0080
0,0060
0,0040
0,0020
0,0000
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
ball
screw
Z,
displacement
in
Y
during
work
cycle
with
iniaal
temperature
298K
at
posiaon
BEH
0,0050
0,0000
-0,0050
-0,0100
-0,0150
-0,0200
-0,0250
-0,0300
-0,0350
displacement (mm)
3600
7200
10800
14400 glass scale YES glass scale NO
ame (s)
112
ball
screw
Z,
displacement
in
Z
during
work
cycle
with
iniaal
temperature
298K
at
posiaon
BEH
0,0000
displacement
(mm)
-0,0200
-0,0400
-0,0600
-0,0800
-0,1000
ame
(s)
3600
7200
10800
14400
glass scale YES glass scale NO
ball
screw
Z,
displacement
in
Y
during
work
cycle
with
dierent
iniaal
temperatures
at
posiaon
BEH
0,02000
displacement
(mm)
0,01000
0,00000
-0,01000
-0,02000
-0,03000
-0,04000
ame
(s)
3600
7200
10800
14400
glass
scale
YES
293K
glass
scale
YES
295K
glass
scale
YES
298K
ball
screw
Z,
displacement
in
Y
during
work
cycle
with
dierent
iniaal
temperatures
at
posiaon
BEH
0,040000
displacement
(mm)
0,030000
0,020000
0,010000
0,000000
-0,010000
-0,020000
3600
7200
10800
14400
ame
(s)
glass
scale
NO
293K
glass
scale
NO
295K
glass
scale
NO
298K
113
ball
screw
Z,
displacement
in
X
during
work
cycle
with
iniaal
temperature
293K
at
posiaon
CFG
0,0140
0,0120
0,0100
0,0080
0,0060
0,0040
0,0020
0,0000
3600
7200
10800
14400
ame
(s)
displacement
(mm)
glass scale YES glass scale NO
ball
screw
Z,
displacement
in
Y
during
work
cycle
with
iniaal
temperature
293K
at
posiaon
CFG
0,0140
0,0120
0,0100
0,0080
0,0060
0,0040
0,0020
0,0000
3600
7200
10800
14400
ame
(s)
displacement
(mm)
glass scale YES glass scale NO
ball
screw
Z,
displacement
in
Z
during
work
cycle
with
iniaal
temperature
293K
at
posiaon
CFG
0,0600
displacement
(mm)
0,0500
0,0400
0,0300
0,0200
0,0100
0,0000
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
114
ball
screw
Z,
displacement
in
X
during
work
cycle
with
iniaal
temperature
295K
at
posiaon
CFG
0,0140
0,0120
0,0100
0,0080
0,0060
0,0040
0,0020
0,0000
3600
7200
10800
14400
ame
(s)
displacement
(mm)
glass scale YES glass scale NO
ball
screw
Z,
displacement
in
Y
during
work
cycle
with
iniaal
temperature
295K
at
posiaon
CFG
3600
7200
10800
14400
0,0000 displacement (mm)
-0,0020 -0,0040 -0,0060 -0,0080 -0,0100 -0,0120 -0,0140 -0,0160
glass scale YES glass scale NO
ame (s)
ball
screw
Z,
displacement
in
Z
during
work
cycle
with
iniaal
temperature
295K
at
posiaon
CFG
0,0250
0,0200
0,0150
0,0100
0,0050
0,0000
-0,0050
-0,0100
-0,0150
displacement (mm)
glass scale YES 3600 7200 10800 14400 glass scale NO
ame (s)
115
ball
screw
Z,
displacement
in
X
during
work
cycle
with
iniaal
temperature
298K
at
posiaon
CFG
0,0120
displacement
(mm)
0,0100
0,0080
0,0060
0,0040
0,0020
0,0000
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
ball
screw
Z,
displacement
in
Y
during
work
cycle
with
iniaal
temperature
298K
at
posiaon
CFG
0,0000
displacement
(mm)
-0,0100
-0,0200
-0,0300
-0,0400
-0,0500
ame
(s)
3600
7200
10800
14400
glass scale YES glass scale NO
ball
screw
Z,
displacement
in
Z
during
work
cycle
with
iniaal
temperature
298K
at
posiaon
CFG
0,0000
displacement
(mm)
-0,0100
-0,0200
-0,0300
-0,0400
-0,0500
-0,0600
-0,0700
ame
(s)
glass
scale
YES
glass
scale
NO
3600
7200
10800
14400
116
ball
screw
Z,
displacement
in
Y
during
work
cycle
with
dierent
iniaal
temperatures
at
posiaon
CFG
0,0200
displacement
(mm)
0,0100
0,0000
-0,0100
-0,0200
-0,0300
-0,0400
-0,0500
ame
(s)
3600
7200
10800
14400
glass
scale
YES
293K
glass
scale
YES
295K
glass
scale
YES
298K
ball
screw
Z,
displacement
in
Y
during
work
cycle
with
dierent
iniaal
temperatures
at
posiaon
CFG
0,0200
displacement
(mm)
0,0100
0,0000
-0,0100
-0,0200
-0,0300
-0,0400
-0,0500
ame
(s)
3600
7200
10800
14400
glass
scale
NO
293K
glass
scale
NO
295K
glass
scale
NO
298K
Tool,
displacement
in
X
during
work
cycle
with
iniaal
temperature
293K
at
posaaon
BEH
0,06000
displacement
(mm)
0,05000
0,04000
0,03000
0,02000
0,01000
0,00000
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
117
Tool,
displacement
in
Y
during
work
cycle
with
iniaal
temperature
293K
at
posiaon
BEH
0,10000
displacement
(mm)
0,08000
0,06000
0,04000
0,02000
0,00000
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
Tool,
displacement
in
Z
during
work
cycle
with
iniaal
temperature
293K
at
posiaon
BEH
0,16000
0,14000
0,12000
0,10000
0,08000
0,06000
0,04000
0,02000
0,00000
3600
7200
10800
14400
ame
(s)
displacement
(mm)
glass scale YES glass scale NO
Tool,
displacement
in
X
during
work
cycle
with
iniaal
temperature
295K
at
posiaon
BEH
0,0600
dispacement
(mm)
0,0500
0,0400
0,0300
0,0200
0,0100
0,0000
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
118
Tool,
displacemtent
in
Y
during
work
cycle
with
iniaal
temperature
295K
at
posiaon
BEH
0,0800
displacement
(mm)
0,0600
0,0400
0,0200
0,0000
-0,0200
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
Tool,
displacement
in
Z
during
work
cycle
with
iniaal
temperature
295K
at
posiaon
BEH
0,1200
0,1000
0,0800
0,0600
0,0400
0,0200
0,0000
-0,0200
-0,0400
displacement (mm)
glass scale YES glass scale NO 3600 7200 10800 14400
ame (s)
Tool,
displacement
in
X
during
work
cycle
with
iniaal
temperature
298K
at
posiaon
BEH
0,0700
0,0600
0,0500
0,0400
0,0300
0,0200
0,0100
0,0000
3600
7200
10800
14400
ame
(s)
displacement
(mm)
glass scale YES glass scale NO
119
Tool,
displacement
in
Y
during
work
cycle
with
iniaal
temperature
298K
at
posiaon
BEH
0,0600
displacement
(mm)
0,0400
0,0200
0,0000
-0,0200
-0,0400
3600
7200
10800
14400
glass
scale
YES
glass
scale
NO
ame (s)
Tool,
displacement
in
Z
during
work
cycle
with
iniaal
temperature
298K
at
posiaon
BEH
0,0600
0,0400
0,0200
0,0000
-0,0200
-0,0400
-0,0600
-0,0800
-0,1000
displacement (mm)
3600
7200
10800
14400
glass scale YES glass scale NO
ame (s)
Tool,
displacement
in
Z
during
work
cycle
with
dierent
iniaal
temperatures
at
posiaon
BEH
0,15000
displacement
(mm)
0,10000
0,05000
0,00000
-0,05000
-0,10000
3600
7200
10800
14400
glass
scale
YES
293K
glass
scale
YES
295K
glass
scale
YES
298K
ame (s)
120
Tool,
displacement
in
Z
during
work
cycle
with
dierent
iniaal
temperatures
at
posiaon
BEH
0,200000
displacement
(mm)
0,150000
0,100000
0,050000
0,000000
-0,050000
-0,100000
3600
7200
10800
14400
ame
(s)
glass
scale
NO
293K
glass
scale
NO
295K
glass
scale
NO
298K
Tool,
displacement
in
X
during
work
cycle
with
iniaal
temperature
293K
at
posaaon
CFG
0,0600
displacement
(mm)
0,0500
0,0400
0,0300
0,0200
0,0100
0,0000
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
Tool,
displacement
in
Y
during
work
cycle
with
iniaal
temperature
293K
at
posiaon
CFG
0,0600
displacement
(mm)
0,0500
0,0400
0,0300
0,0200
0,0100
0,0000
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
121
Tool,
displacement
in
Z
during
work
cycle
with
iniaal
temperature
293K
at
posiaon
CFG
0,2000
displacement
(mm)
0,1500
0,1000
0,0500
0,0000
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
Tool,
displacement
in
X
during
work
cycle
with
iniaal
temperature
295K
at
posiaon
CFG
0,0600
dispacement
(mm)
0,0500
0,0400
0,0300
0,0200
0,0100
0,0000
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
Tool,
displacemtent
in
Y
during
work
cycle
with
iniaal
temperature
295K
at
posiaon
CFG
0,0500
displacement
(mm)
0,0400
0,0300
0,0200
0,0100
0,0000
-0,0100
-0,0200
3600
7200
10800
14400
glass
scale
YES
glass
scale
NO
ame (s)
122
Tool,
displacement
in
Z
during
work
cycle
with
iniaal
temperature
295K
at
posiaon
CFG
0,1400
0,1200
0,1000
0,0800
0,0600
0,0400
0,0200
0,0000
-0,0200
displacement (mm)
glass scale YES glass scale NO
3600
7200 10800 ame (s)
14400
Tool,
displacement
in
X
during
work
cycle
with
iniaal
temperature
298K
at
posiaon
CFG
0,0700
0,0600
0,0500
0,0400
0,0300
0,0200
0,0100
0,0000
3600
7200
10800
14400
ame
(s)
displacement
(mm)
glass scale YES glass scale NO
Tool,
displacement
in
Y
during
work
cycle
with
iniaal
temperature
298K
at
posiaon
CFG
0,0200
displacement
(mm)
0,0100
0,0000
-0,0100
-0,0200
-0,0300
-0,0400
ame
(s)
3600
7200
10800
14400
glass
scale
YES
glass
scale
NO
123
Tool,
displacement
in
Z
during
work
cycle
with
iniaal
temperature
298K
at
posiaon
CFG
0,1000
0,0800
0,0600
0,0400
0,0200
0,0000
-0,0200
-0,0400
-0,0600
-0,0800
displacement (mm)
glass scale YES 3600 7200 10800 14400 glass scale NO
ame (s)
Tool,
displacement
in
Z
during
work
cycle
with
dierent
iniaal
temperatures
at
posiaon
CFG
0,1500
displacement
(mm)
0,1000
0,0500
0,0000
-0,0500
-0,1000
3600
7200
10800
14400
glass
scale
YES
293K
glass
scale
YES
295K
glass
scale
YES
298K
ame (s)
Tool,
displacement
in
Z
during
work
cycle
with
dierent
iniaal
temperatures
at
posiaon
CFG
0,2000
displacement
(mm)
0,1500
0,1000
0,0500
0,0000
-0,0500
3600
7200
10800
14400
ame
(s)
glass
scale
NO
293K
glass
scale
NO
295K
glass
scale
NO
298K
124
Table,
displacement
in
X
during
work
cycle
with
iniaal
temperature
293K
at
posiaon
BEH
0,02
displacement
(mm)
0,015
0,01
0,005
0
-0,005
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
Table,
displacement
in
Y
during
work
cycle
with
iniaal
temperature
293K
at
posiaon
BEH
0,0007
0,0006
0,0005
0,0004
0,0003
0,0002
0,0001
0
3600
7200
10800
14400
ame
(s)
displacement
(mm)
glass scale YES glass scale NO
Table,
displacement
in
Z
during
work
cycle
with
iniaal
temperature
293K
at
posiaon
BEH
0,0012
displacement
(mm)
0,001
0,0008
0,0006
0,0004
0,0002
0
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
125
Table,
displacement
in
X
during
work
cycle
with
iniaal
temperature
295K
at
posiaon
BEH
0,0350
0,0300
0,0250
0,0200
0,0150
0,0100
0,0050
0,0000
3600
7200
10800
14400
ame
(s)
displacement
(mm)
glass scale YES glass scale NO
Table,
displacement
in
Y
during
work
cycle
with
iniaal
temperature
295K
at
posiaon
BEH
0,0000
displacement
(mm)
-0,0020
-0,0040
-0,0060
-0,0080
-0,0100
ame
(s)
3600
7200
10800
14400
glass scale YES glass scale NO
Table,
displacement
in
Z
during
work
cycle
with
iniaal
temperature
295K
at
posiaon
BEH
-0,0114
-0,0116
-0,0118
-0,0120
-0,0122
-0,0124
-0,0126
-0,0128
-0,0130
-0,0132
3600
7200
10800
14400
displacement (mm)
glass scale YES glass scale NO
ame (s)
126
Table,
displacement
in
X
during
work
cycle
with
iniaal
temperature
298K
at
posiaon
BEH
0,0600
displacement
(mm)
0,0500
0,0400
0,0300
0,0200
0,0100
0,0000
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
Table,
displacement
in
Y
during
work
cycle
with
iniaal
temperature
298K
at
posiaon
BEH
0,0000
displacement
(mm)
-0,0050
-0,0100
-0,0150
-0,0200
-0,0250
ame
(s)
3600
7200
10800
14400
glass scale YES glass scale NO
Table,
displacement
in
Z
during
work
cycle
with
iniaal
temperature
298K
at
posiaon
BEH
-0,0310
displacement
(mm)
-0,0320
-0,0330
-0,0340
-0,0350
-0,0360
-0,0370
ame
(s)
glass
scale
YES
glass
scale
NO
3600
7200
10800
14400
127
Table,
displacement
in
X
during
work
cycle
with
dierent
iniaal
temperatures
at
posiaon
BEH
0,06
displacement
(mm)
0,05
0,04
0,03
0,02
0,01
0
3600
7200
10800
14400
ame
(s)
glass
scale
NO
293K
glass
scale
NO
295K
glass
scale
NO
298K
Table,
displacement
in
X
during
work
cycle
with
iniaal
temperature
293K
at
posiaon
CFG
0,0500
displacement
(mm)
0,0400
0,0300
0,0200
0,0100
0,0000
-0,0100
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
Table,
displacement
in
Y
during
work
cycle
with
iniaal
temperature
293K
at
posiaon
CFG
0,0006
displacement
(mm)
0,0005
0,0004
0,0003
0,0002
0,0001
0,0000
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
128
Table,
displacement
in
Z
during
work
cycle
with
iniaal
temperature
293K
at
posiaon
CFG
0,0010
0,0010
0,0010
0,0010
0,0010
0,0010
0,0010
0,0010
0,0010
0,0010
3600
7200
10800
14400
ame
(s)
displacement
(mm)
glass scale YES glass scale NO
Table,
displacement
in
X
during
work
cycle
with
iniaal
temperature
295K
at
posiaon
CFG
0,0700
0,0600
0,0500
0,0400
0,0300
0,0200
0,0100
0,0000
3600
7200
10800
14400
ame
(s)
displacement
(mm)
glass scale YES glass scale NO
Table,
displacement
in
Z
during
work
cycle
with
iniaal
temperature
295K
at
posiaon
CFG
0,0000
displacement
(mm)
-0,0020
-0,0040
-0,0060
-0,0080
-0,0100
-0,0120
ame
(s)
glass
scale
YES
glass
scale
NO
3600
7200
10800
14400
129
Table,
displacement
in
Y
during
work
cycle
with
iniaal
temperature
295K
at
posiaon
CFG
0,0000
displacement
(mm)
-0,0020
-0,0040
-0,0060
-0,0080
-0,0100
ame
(s)
3600
7200
10800
14400
glass scale YES glass scale NO
Table,
displacement
in
X
during
work
cycle
with
iniaal
temperature
298K
at
posiaon
CFG
0,1200
displacement
(mm)
0,1000
0,0800
0,0600
0,0400
0,0200
0,0000
3600
7200
10800
14400
ame
(s)
glass
scale
YES
glass
scale
NO
Table,
displacement
in
Y
during
work
cycle
with
iniaal
temperature
298K
at
posiaon
CFG
-0,0194
-0,0196
-0,0198
-0,0200
-0,0202
-0,0204
-0,0206
-0,0208
-0,0210
-0,0212
displacement
(mm)
3600
7200
10800
14400
glass scale YES glass scale NO
ame (s)
130
Table,
displacement
in
Z
during
work
cycle
with
iniaal
temperature
298K
at
posiaon
CFG
-0,0210
displacement
(mm)
-0,0220
-0,0230
-0,0240
-0,0250
-0,0260
-0,0270
ame
(s)
glass
scale
YES
glass
scale
NO
3600
7200
10800
14400
Table,
displacement
in
X
during
work
cycle
with
dierent
iniaal
temperatures
at
posiaon
CFG
0,0500
displacement
(mm)
0,0400
0,0300
0,0200
0,0100
0,0000
-0,0100
3600
7200
10800
14400
ame
(s)
glass
scale
YES
293K
glass
scale
YES
295K
glass
scale
YES
298K
Table,
displacement
in
X
during
work
cycle
with
dierent
iniaal
temperatures
at
posiaon
CFG
0,1200
displacement
(mm)
0,1000
0,0800
0,0600
0,0400
0,0200
0,0000
3600
7200
10800
14400
ame
(s)
glass
scale
NO
293K
glass
scale
NO
295K
glass
scale
NO
298K
131
11. References [1] Heidenhain linear scales http://www.heidenhain.com [2] Luis Miguel Sanchez-Brea and Tomas Morlanes 2008 Metrological errors in optical encoders Meas. Sci. Technol. 19 [3] Ignacio Alejandre and Mariano Arts 2006 Analysis of the Precision Lost in Optical Linear Encoders as a Consequence of Reticule Deformation, Informacion Tecnologica v 17, n6 La Serena 2006. [4] Thomas P. Moran and John M. Carroll 1996 Design Rationale: Concepts, Techniques and Use Lawerence Erlbaum Associates. [5] M. Weck, P. McKeown, R. Bonse and U. Herbst: Reduction and compensation of Thermal Errors in Machine Tools, Annals of the CIRP, Vol 44, Issue 2, 1995, pages 589- 598. [6] L.K. Kayak, E.E. Sharova and O.V. Yachmentsev: Linear and Angular measurements. Metrological means of increasing the accuracy of precision machine tools, UDC (531.71=531.74).088:621.9 [7] L.K. Kayak: Linear and Angular measurements. Standardization of Linear measurements, UDC 389.6:531.71 [8] P. Compton and R. Jansen 1989 A philosophical basis for knowledge acquisition, European knowledge acquisition for knowledge based systems workshop 1989 [9] Clyde W. Holsapple and Andrew B. Whinston, Manager's Guide to Expert Systems Using Guru [10] SKF Group, Interactive engineering catalog: http://www.skf.com/portal/skf/home/products?maincatalogue=1&newlink=first&lang =en [11] Tae Jo Ko, Tae-weon Gim and Jae-yong Ha: Particular behavior of spindle thermal deformation by thermal bending, International Journal of Machine Tool and Manufacture 43 (2003) 17-23 [12] Jong-Jin Kim, Young Hun Jeong and Dong-Woo Cho: Thermal behavior of a machine tool equipped with linear motors, International Journal of Machine Tool and Manufacture 44(2004) 749-758 [13] H.J. Pahk and S.W. Lee: Thermal Error Measurement and Real Time Compensation System for the CNC Machine Tools Incorporating the Spindle Thermal Error and the Feed Axis Thermal Error, , Int J Adv Technol(2002) 20:487-494
132
[14]
Bernd
Bossmanns
A
Power
flow
model
for
high
speed
motorized
spindle,
J.Manuf.
Sci.
Eng.
2001,
vol
123,
issue
3,
493
[15]
Eugene
A.
Avallone,
Theodore
Baumeister
Marks'
Standard
Handbook
for
Mechanical
Engineers,
McGraw-Hill
Professional
2006,
ISBN:
0071428674
133
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